Electrosurgical cartridge for use in thin profile surgical cutting and stapling instrument

ABSTRACT

The present disclosure provides a surgical instrument that includes an end effector configured to slideably receive a cutting member. The end effector includes a first and second jaw that is movable relative to the first jaw, a hot zone in a center portion of the end effector, and cool zones in both side portions of the end effector. The first and second jaws define an elongate slot therebetween, to slideably receive the cutting member within the elongate slot to cut tissue located between the first and second jaws. The first jaw includes a first insulative layer and a second insulative layer in the hot zone, a first electrode layer on the first insulative layer, a second electrode layer on the second insulative layer, and heat sink layers in the cool zones. The heat sink layers are configured to cool the tissue in the cool zones to minimize lateral thermal spread.

TECHNICAL FIELD

The present disclosure relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BACKGROUND

In various open, endoscopic, and/or laparoscopic surgeries, for example,it may be desirable to coagulate, seal, and/or fuse tissue. One methodof sealing tissue relies upon the application of energy, such aselectrical energy, for example, to tissue captured or clamped within anend-effector or an end-effector assembly of a surgical instrument inorder to cause thermal effects within the tissue. Various mono-polar andbi-polar radio frequency (RF) surgical instruments and surgicaltechniques have been developed for such purposes. In general, thedelivery of RF energy to the captured tissue can elevate the temperatureof the tissue and, as a result, the energy can at least partiallydenature proteins within the tissue. Such proteins, such as collagen,for example, can be denatured into a proteinaceous amalgam thatintermixes and fuses, or seals, together as the proteins renature. Asthe treated region heals over time, this biological seal may bereabsorbed by the body's wound-healing process.

SUMMARY

In one aspect, an surgical instrument includes an end effectorconfigured to slideably receive a cutting member. The end effectorincludes a first jaw, a second jaw that is movable relative to the firstjaw, a hot zone in a center portion of the end effector, a first coolzone in a left side portion of the end effector, and a second cool zonein a right side portion of the end effector. The first jaw and thesecond jaw define an elongate slot therebetween to slideably receive thecutting member within the elongate slot to cut tissue located betweenthe first jaw and the second jaw. The elongate slot is located in thecenter portion of the end effector. The first jaw includes a firstinsulative layer and a second insulative layer in the hot zone, a firstelectrode layer on the first insulative layer, a second electrode layeron the second insulative layer, a first heat sink layer in the firstcool zone, and a second heat sink layer in the second cool zone. Thefirst insulative layer is on the left side of the elongate slot and thesecond insulative layer is on the right side of the elongate slot. Thefirst electrode layer and the second electrode layer are configured fordirect application of electrosurgical energy to the tissue in the hotzone. The first heat sink layer and the second heat sink layer areconfigured to cool the tissue in the first and second cool zones tominimize lateral thermal spread.

In an aspect, an surgical instrument includes an end effector configuredto slideably receive a blade. The end effector includes a first jaw, asecond jaw that is movable relative to the first jaw, a hot zone in acenter portion of the end effector, a first cool zone in a left sideportion of the end effector, a second cool zone in a right side portionof the end effector, and a dissector tip at a distal end of the endeffector. The first jaw and the second jaw define an elongate slottherebetween to slideably receive a blade within the elongate slot tocut tissue located between the first jaw and the second jaw. Theelongate slot is located in the center portion of the end effector. Thefirst jaw includes a first insulative layer and a second insulativelayer in the hot zone, a first electrode layer on the first insulativelayer, a second electrode layer on the second insulative layer, a firstheat sink layer in the first cool zone, and a second heat sink layer inthe second cool zone. The first insulative layer is on the left side ofthe elongate slot and the second insulative layer is on the right sideof the elongate slot. The first electrode layer and the second electrodelayer are configured for direct application of electrosurgical energy tothe tissue in the hot zone. Each of the first electrode layer and thesecond electrode layer comprises a direct contact metal electrode Thefirst heat sink layer and the second heat sink layer are configured tocool the tissue in the first and second cool zones to minimize lateralthermal spread.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects and featuresdescribed above, further aspects and features will become apparent byreference to the drawings and the following detailed description.

FIGURES

The novel features of the aspects described herein are set forth withparticularity in the appended claims. These aspects, however, both as toorganization and methods of operation may be better understood byreference to the following description, taken in conjunction with theaccompanying drawings.

FIG. 1 is a perspective view of a surgical system including a handleassembly coupled to an interchangeable surgical tool assembly that isconfigured to be used in connection with conventional surgicalstaple/fastener cartridges and radio frequency (RF) cartridges accordingto one aspect of this disclosure.

FIG. 2 is an exploded perspective assembly view of the surgical systemof FIG. 1 according to one aspect of this disclosure.

FIG. 3 is another exploded perspective assembly view of portions of thehandle assembly and interchangeable surgical tool assembly of FIGS. 1and 2 according to one aspect of this disclosure.

FIG. 4 is an exploded assembly view of a proximal portion of theinterchangeable surgical tool assembly of FIGS. 1-3 according to oneaspect of this disclosure.

FIG. 5 is another exploded assembly view of a distal portion of theinterchangeable surgical tool assembly of FIGS. 1-5 according to oneaspect of this disclosure.

FIG. 6 is a partial cross-sectional view of the end effector depicted inFIGS. 1-5 supporting an RF cartridge therein and with tissue clampedbetween the cartridge and the anvil according to one aspect of thisdisclosure.

FIG. 7 is a partial cross-sectional view of the anvil of FIG. 6according to one aspect of this disclosure.

FIG. 8 is another exploded assembly view of a portion of theinterchangeable surgical tool assembly of FIGS. 1-5 according to oneaspect of this disclosure.

FIG. 9 is another exploded assembly view of the interchangeable surgicaltool assembly and handle assembly of FIGS. 1 and 2 according to oneaspect of this disclosure.

FIG. 10 is a perspective view of an RF cartridge and an elongate channelof the interchangeable surgical tool assembly of FIGS. 1-5 according toone aspect of this disclosure.

FIG. 11 is a partial perspective view of portions of the RF cartridgeand elongate channel of FIG. 10 with a knife member according to oneaspect of this disclosure.

FIG. 12 is another perspective view of the RF cartridge installed in theelongate channel of FIG. 10 and illustrating a portion of a flexibleshaft circuit arrangement according to one aspect of this disclosure.

FIG. 13 is a cross-sectional end view of the RF cartridge and elongatechannel of FIG. 12 taken along lines 13-13 in FIG. 12 according to oneaspect of this disclosure.

FIG. 14 is a top cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIGS. 1 and 5 with the endeffector thereof in an articulated position according to one aspect ofthis disclosure.

FIG. 15 is a perspective view of an onboard circuit board arrangementand RF generator plus configuration according to one aspect of thisdisclosure.

FIGS. 16A-16B is a block diagram of a control circuit of the surgicalinstrument of FIG. 1 spanning two drawing sheets according to one aspectof this disclosure.

FIG. 17 is a block diagram of the control circuit of the surgicalinstrument of FIG. 1 illustrating interfaces between the handleassembly, the power assembly, and the handle assembly and theinterchangeable shaft assembly according to one aspect of thisdisclosure.

FIG. 18 is a schematic diagram of a surgical instrument configured tocontrol various functions according to one aspect of this disclosure.

FIG. 19 is a schematic cross-sectional view of an electrosurgical endeffector according to one aspect of this disclosure.

FIG. 20 is a perspective view of an end effector according to one aspectof this disclosure.

DESCRIPTION

Applicant of the present application owns the following patentapplications filed on Jun. 28, 2017 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/636,096, titled SURGICAL SYSTEMCOUPLABLE WITH STAPLE CARTRIDGE AND RADIO FREQUENCY CARTRIDGE, ANDMETHOD OF USING SAME, by inventors Jeffrey D. Messerly et al., filedJun. 28, 2017, now U.S. Patent Application Publication No. 2019/0000478.

U.S. patent application Ser. No. 15/636,103, titled SYSTEMS AND METHODSOF DISPLAYING SURGICAL INSTRUMENT STATUS, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017, now U.S. Patent ApplicationPublication No. 2019/0000533.

U.S. patent application Ser. No. 15/636,110, titled SHAFT MODULECIRCUITRY ARRANGEMENTS, by inventors Jeffrey D. Messerly et al., filedJun. 28, 2017, now U.S. Patent Application Publication No. 2019/0000525.

U.S. patent application Ser. No. 15/636,116, titled SYSTEMS AND METHODSFOR CONTROLLING CONTROL CIRCUITS FOR INDEPENDENT ENERGY DELIVERY OVERSEGMENTED SECTIONS, by inventors Jeffrey D. Messerly et al., filed Jun.28, 2017, now U.S. Patent Application Publication No. 2019/0000534.

U.S. patent application Ser. No. 15/636,123, titled FLEXIBLE CIRCUITARRANGEMENT FOR SURGICAL FASTENING INSTRUMENTS, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017, now U.S. Patent ApplicationPublication No. 2019/0000531.

U.S. patent application Ser. No. 15/636,134, titled SURGICAL SYSTEMCOUPLEABLE WITH STAPLE CARTRIDGE AND RADIO FREQUENCY CARTRIDGE, ANDHAVING A PLURALITY OF RADIO-FREQUENCY ENERGY RETURN PATHS, by inventorsJeffrey D. Messerly et al., filed Jun. 28, 2017, now U.S. PatentApplication Publication No. 2019/0000535.

U.S. patent application Ser. No. 15/636,144, titled SYSTEMS AND METHODSFOR CONTROLLING CONTROL CIRCUITS FOR AN INDEPENDENT ENERGY DELIVERY OVERSEGMENTED SECTIONS, by inventors David C. Yates et al., filed Jun. 28,2017, now U.S. Pat. No. 10,265,120.

U.S. patent application Ser. No. 15/636,150, titled SURGICAL ENDEFFECTOR FOR APPLYING ELECTROSURGICAL ENERGY TO DIFFERENT ELECTRODES ONDIFFERENT TIME PERIODS, by inventors Tamara Widenhouse et al., filedJun. 28, 2017, now U.S. Patent Application Publication No. 2019/0000537.

U.S. patent application Ser. No. 15/636,169, titled SURGICAL ENDEFFECTOR TO ADJUST JAW COMPRESSION, by inventors Frederick E. Shelton, IV et al., filed Jun. 28, 2017, now U.S. Patent Application PublicationNo. 2019/0000532.

U.S. patent application Ser. No. 15/636,177, titled CARTRIDGEARRANGEMENTS FOR SURGICAL CUTTING AND FASTENING INSTRUMENTS WITH LOCKOUTDISABLEMENT FEATURES, by inventors Jason L. Harris et al., filed Jun.28, 2017, now U.S. Patent Application Publication No. 2019/0000479.

U.S. patent application Ser. No. 15/636,180, titled SURGICAL CUTTING ANDFASTENING INSTRUMENTS WITH DUAL POWER SOURCES, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017, now U.S. Patent ApplicationPublication No. 2019/0000539.

Electrosurgical devices may be used in many surgical operations.Electrosurgical devices may apply electrical energy to tissue in orderto treat tissue. An electrosurgical device may comprise an instrumenthaving a distally mounted end effector comprising one or moreelectrodes. The end effector can be positioned against tissue such thatelectrical current may be introduced into the tissue. Electrosurgicaldevices can be configured for monopolar or bipolar operation. Duringmonopolar operation, current may be introduced into the tissue by anactive (or source) electrode on the end effector and returned through areturn electrode. The return electrode may be a grounding pad andseparately located on a patient's body. During bipolar operation,current may be introduced into and returned from the tissue by theactive and return electrodes, respectively, of the end effector.

The end effector may include two or more jaw members. At least one ofthe jaw members may have at least one electrode. At least one jaw may bemoveable from a position spaced apart from the opposing jaw forreceiving tissues to a position in which the space between the jawmembers is less than that of the first position. This movement of themoveable jaw may compress the tissue held between. Heat generated by thecurrent flow through the tissue in combination with the compressionachieved by the jaw's movement may form hemostatic seals within thetissue and/or between tissues and, thus, may be particularly useful forsealing blood vessels, for example. The end effector may comprise acutting member. The cutting member may be movable relative to the tissueand the electrodes to transect the tissue.

Electrosurgical devices also may include mechanisms to clamp tissuetogether, such as a stapling device, and/or mechanisms to sever tissue,such as a tissue knife. An electrosurgical device may include a shaftfor placing the end effector proximate to tissue undergoing treatment.The shaft may be straight or curved, bendable or non-bendable. In anelectrosurgical device including a straight and bendable shaft, theshaft may have one or more articulation joints to permit controlledbending of the shaft. Such joints may permit a user of theelectrosurgical device to place the end effector in contact with tissueat an angle to the shaft when the tissue being treated is not readilyaccessible using an electrosurgical device having a straight,non-bending shaft.

Electrical energy applied by electrosurgical devices can be transmittedto the instrument by a generator in communication with the hand piece.The electrical energy may be in the form of radio frequency (“RF”)energy. RF energy is a form of electrical energy that may be in thefrequency range of 200 kilohertz (kHz) to 1 megahertz (MHz). Inapplication, an electrosurgical instrument can transmit low frequency RFenergy through tissue, which causes ionic agitation, or friction, ineffect resistive heating, thereby increasing the temperature of thetissue. Because a sharp boundary is created between the affected tissueand the surrounding tissue, surgeons can operate with a high level ofprecision and control, without sacrificing un-targeted adjacent tissue.The low operating temperatures of RF energy is useful for removing,shrinking, or sculpting soft tissue while simultaneously sealing bloodvessels. RF energy works particularly well on connective tissue, whichis primarily comprised of collagen and shrinks when contacted by heat.

The RF energy may be in a frequency range described in EN60601-2-2:2009+A11:2011, Definition 201.3.218—HIGH FREQUENCY. Forexample, the frequency in monopolar RF applications may be typicallyrestricted to less than 5 MHz. However, in bipolar RF applications, thefrequency can be almost anything. Frequencies above 200 kHz can betypically used for monopolar applications in order to avoid the unwantedstimulation of nerves and muscles that would result from the use of lowfrequency current. Lower frequencies may be used for bipolarapplications if the risk analysis shows the possibility of neuromuscularstimulation has been mitigated to an acceptable level. Normally,frequencies above 5 MHz are not used in order to minimize the problemsassociated with high frequency leakage currents. Higher frequencies may,however, be used in the case of bipolar applications. It is generallyrecognized that 10 mA is the lower threshold of thermal effects ontissue.

FIGS. 1 and 2 depict a motor-driven surgical system 10 that may be usedto perform a variety of different surgical procedures. In theillustrated arrangement, the surgical system 10 comprises aninterchangeable surgical tool assembly 1000 that is operably coupled toa handle assembly 500. In another surgical system aspect, theinterchangeable surgical tool assembly 1000 may also be effectivelyemployed with a tool drive assembly of a robotically controlled orautomated surgical system. For example, the surgical tool assembly 1000disclosed herein may be employed with various robotic systems,instruments, components and methods such as, but not limited to, thosedisclosed in U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which ishereby incorporated by reference herein in its entirety.

In the illustrated aspect, the handle assembly 500 may comprise a handlehousing 502 that includes a pistol grip portion 504 that can be grippedand manipulated by the clinician. As will be briefly discussed below,the handle assembly 500 operably supports a plurality of drive systemsthat are configured to generate and apply various control motions tocorresponding portions of the interchangeable surgical tool assembly1000. As shown in FIG. 2, the handle assembly 500 may further include ahandle frame 506 that operably supports the plurality of drive systems.For example, the handle frame 506 can operably support a “first” orclosure drive system, generally designated as 510, which may be employedto apply closing and opening motions to the interchangeable surgicaltool assembly 1000. In at least one form, the closure drive system 510may include an actuator in the form of a closure trigger 512 that ispivotally supported by the handle frame 506. Such arrangement enablesthe closure trigger 512 to be manipulated by a clinician such that whenthe clinician grips the pistol grip portion 504 of the handle assembly500, the closure trigger 512 may be easily pivoted from a starting or“unactuated” position to an “actuated” position and more particularly toa fully compressed or fully actuated position. In use, to actuate theclosure drive system 510, the clinician depresses the closure trigger512 towards the pistol grip portion 504. As described in further detailin U.S. patent application Ser. No. 14/226,142, entitled SURGICALINSTRUMENT COMPRISING A SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2015/0272575, which is hereby incorporated by referencein its entirety herein, when the clinician fully depresses the closuretrigger 512 to attain the full closure stroke, the closure drive system510 is configured to lock the closure trigger 512 into the fullydepressed or fully actuated position. When the clinician desires tounlock the closure trigger 512 to permit it to be biased to theunactuated position, the clinician simply activates a closure releasebutton assembly 518 which enables the closure trigger to return tounactuated position. The closure release button assembly 518 may also beconfigured to interact with various sensors that communicate with amicrocontroller in the handle assembly 500 for tracking the position ofthe closure trigger 512. Further details concerning the configurationand operation of the closure release button assembly 518 may be found inU.S. Patent Application Publication No. 2015/0272575.

In at least one form, the handle assembly 500 and the handle frame 506may operably support another drive system referred to herein as a firingdrive system 530 that is configured to apply firing motions tocorresponding portions of the interchangeable surgical tool assemblythat is attached thereto. As was described in detail in U.S. PatentApplication Publication No. 2015/0272575, the firing drive system 530may employ an electric motor 505 that is located in the pistol gripportion 504 of the handle assembly 500. In various forms, the motor 505may be a DC brushed driving motor having a maximum rotation of,approximately, 25,000 RPM, for example. In other arrangements, the motor505 may include a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor. The motor505 may be powered by a power source 522 that in one form may comprise aremovable power pack. The power pack may support a plurality of LithiumIon (“LI”) or other suitable batteries therein. A number of batteriesthat may be connected in series may be used as the power source 522 forthe surgical system 10. In addition, the power source 522 may bereplaceable and/or rechargeable.

The electric motor 505 is configured to axially drive a longitudinallymovable drive member 540 (FIG. 3) in a distal and proximal directionsdepending upon the polarity of the motor. For example, when the motor505 is driven in one rotary direction, the longitudinally movable drivemember 540 will be axially driven in a distal direction “DD”. When themotor 505 is driven in the opposite rotary direction, the longitudinallymovable drive member 540 will be axially driven in a proximal direction“PD”. The handle assembly 500 can include a switch 513 which can beconfigured to reverse the polarity applied to the electric motor 505 bythe power source 522 or otherwise control the motor 505. The handleassembly 500 can also include a sensor or sensors (not shown) that isconfigured to detect the position of the drive member and/or thedirection in which the drive member is being moved. Actuation of themotor 505 can be controlled by a firing trigger (not shown) that isadjacent to the closure trigger 512 and pivotally supported on thehandle assembly 500. The firing trigger may be pivoted between anunactuated position and an actuated position. The firing trigger may bebiased into the unactuated position by a spring or other biasingarrangement such that when the clinician releases the firing trigger, itmay be pivoted or otherwise returned to the unactuated position by thespring or biasing arrangement. In at least one form, the firing triggercan be positioned “outboard” of the closure trigger 512. As discussed inU.S. Patent Application Publication No. 2015/0272575, the handleassembly 500 may be equipped with a firing trigger safety button (notshown) to prevent inadvertent actuation of the firing trigger. When theclosure trigger 512 is in the unactuated position, the safety button iscontained in the handle assembly 500 where the clinician cannot readilyaccess it and move it between a safety position preventing actuation ofthe firing trigger and a firing position wherein the firing trigger maybe fired. As the clinician depresses the closure trigger 512, the safetybutton and the firing trigger pivot down wherein they can then bemanipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 mayhave a rack of teeth 542 formed thereon for meshing engagement with acorresponding drive gear arrangement (not shown) that interfaces withthe motor. See FIG. 3. Further details regarding those features may befound in U.S. Patent Application Publication No. 2015/0272575. In atleast one arrangement, however, the longitudinally movable drive member540 is insulated to protect it from inadvertent RF energy. At least oneform also includes a manually-actuatable “bailout” assembly that isconfigured to enable the clinician to manually retract thelongitudinally movable drive member 540 should the motor 505 becomedisabled. The bailout assembly may include a lever or bailout handleassembly that is stored within the handle assembly 500 under areleasable door 550. See FIG. 2. The lever may be configured to bemanually pivoted into ratcheting engagement with the teeth in the drivemember. Thus, the clinician can manually retract the drive member 540 byusing the bailout handle assembly to ratchet the drive member in theproximal direction “PD”. U.S. Pat. No. 8,608,045, entitled POWEREDSURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRINGSYSTEM, the entire disclosure of which is hereby incorporated byreference herein, discloses bailout arrangements and other components,arrangements and systems that may also be employed with any one of thevarious interchangeable surgical tool assemblies disclosed herein.

In the illustrated aspect, the interchangeable surgical tool assembly1000 includes a surgical end effector 1500 that comprises a first jaw1600 and a second jaw 1800. In one arrangement, the first jaw 1600comprises an elongate channel 1602 that is configured to operablysupport a conventional (mechanical) surgical staple/fastener cartridge1400 (FIG. 4) or a radio frequency (RF) cartridge 1700 (FIGS. 1 and 2)therein. The second jaw 1800 comprises an anvil 1810 that is pivotallysupported relative to the elongate channel 1602. The anvil 1810 may beselectively moved toward and away from a surgical cartridge supported inthe elongate channel 1602 between open and closed positions by actuatingthe closure drive system 510. In the illustrated arrangement, the anvil1810 is pivotally supported on a proximal end portion of the elongatechannel 1602 for selective pivotal travel about a pivot axis that istransverse to the shaft axis SA. Actuation of the closure drive system510 may result in the distal axial movement of a proximal closure memberor proximal closure tube 1910 that is attached to an articulationconnector 1920.

Turning to FIG. 4, the articulation connector 1920 includes upper andlower tangs 1922, 1924 that protrude distally from a distal end of thearticulation connector 1920 to be movably coupled to an end effectorclosure sleeve or distal closure tube segment 1930. See FIG. 3. Thedistal closure tube segment 1930 includes an upper tang 1932 and a lowertang (not shown) that protrude proximally from a proximal end thereof.An upper double pivot link 1940 includes proximal and distal pins 1941,1942 that engage corresponding holes in the upper tangs 1922, 1932 ofthe articulation connector 1920 and distal closure tube segment 1930,respectively. Similarly, a lower double pivot link 1944 includesproximal and distal pins 1945, 1946 that engage corresponding holes inthe lower tangs 1924 of the articulation connector 1920 and distalclosure tube segment 1930, respectively.

Still referring to FIG. 4, in the illustrated example, the distalclosure tube segment 1930 includes positive jaw opening features or tabs1936, 1938 that correspond with corresponding portions of the anvil 1810to apply opening motions to the anvil 1810 as the distal closure tubesegment 1930 is retracted in the proximal direction PD to a startingposition. Further details regarding the opening and closing of the anvil1810 may be found in U.S. patent application Ser. No. 15/635,621entitled SURGICAL INSTRUMENT WITH POSITIVE JAW OPENING FEATURES, filedon Jun. 28, 2017, the entire disclosure of which is hereby incorporatedby reference herein.

As shown in FIG. 5, in at least one arrangement, the interchangeablesurgical tool assembly 1000 includes a tool frame assembly 1200 thatcomprises a tool chassis 1210 that operably supports a nozzle assembly1240 thereon. As further discussed in detail in U.S. patent applicationSer. No. 15/635,631 entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLECLOSURE MEMBER, filed on Jun. 28, 2017, and which is hereby incorporatedby reference in its entirety herein, the tool chassis 1210 and nozzlearrangement 1240 facilitate rotation of the surgical end effector 1500about a shaft axis SA relative to the tool chassis 1210. Such rotationaltravel is represented by arrow R in FIG. 1. As also shown in FIGS. 4 and5, the interchangeable surgical tool assembly 1000 includes a spineassembly 1250 that operably supports the proximal closure tube 1910 andis coupled to the surgical end effector 1500. In various circumstances,for ease of assembly, the spine assembly 1250 may be fabricated from anupper spine segment 1251 and a lower spine segment 1252 that areinterconnected together by snap features, adhesive, welding, etc. Inassembled form, the spine assembly 1250 includes a proximal end 1253that is rotatably supported in the tool chassis 1210. In onearrangement, for example, the proximal end 1253 of the spine assembly1250 is attached to a spine bearing (not shown) that is configured to besupported within the tool chassis 1210. Such arrangement facilitatesrotatable attachment of the spine assembly 1250 to the tool chassis suchthat the spine assembly 1250 may be selectively rotated about a shaftaxis SA relative to the tool chassis 1210.

As shown in FIG. 4, the upper spine segment 1251 terminates in an upperlug mount feature 1260 and the lower spine segment 1252 terminates in alower lug mount feature 1270. The upper lug mount feature 1260 is formedwith a lug slot 1262 therein that is adapted to mountingly support anupper mounting link 1264 therein. Similarly, the lower lug mount feature1270 is formed with a lug slot 1272 therein that is adapted tomountingly support a lower mounting link 1274 therein. The uppermounting link 1264 includes a pivot socket 1266 therein that is offsetfrom the shaft axis SA. The pivot socket 1266 is adapted to rotatablyreceive therein a pivot pin 1634 that is formed on a channel cap oranvil retainer 1630 that is attached to a proximal end portion 1610 ofthe elongate channel 1602. The lower mounting link 1274 includes lowerpivot pin 1276 that adapted to be received within a pivot hole 1611formed in the proximal end portion 1610 of the elongate channel 1602.The lower pivot pin 1276 as well as the pivot hole 1611 is offset fromthe shaft axis SA. The lower pivot pin 1276 is vertically aligned withthe pivot socket 1266 to define the articulation axis AA about which thesurgical end effector 1500 may articulate relative to the shaft axis SA.See FIG. 1. Although the articulation axis AA is transverse to the shaftaxis SA, in at least one arrangement, the articulation axis AA islaterally offset therefrom and does not intersect the shaft axis SA.

Turning to FIG. 5, a proximal end 1912 of the proximal closure tube 1910is rotatably coupled to a closure shuttle 1914 by a connector 1916 thatis seated in an annular groove 1915 in the proximal closure tube segment1910. The closure shuttle 1914 is supported for axial travel within thetool chassis 1210 and has a pair of hooks 1917 thereon configured toengage the closure drive system 510 when the tool chassis 1210 iscoupled to the handle frame 506. The tool chassis 1210 further supportsa latch assembly 1280 for releasably latching the tool chassis 1210 tothe handle frame 506. Further details regarding the tool chassis 1210and latch assembly 1280 may be found in U.S. patent application Ser. No.15/635,631 entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSUREMEMBER, filed on Jun. 28, 2017 and the entire disclosure of which ishereby incorporated by reference herein.

The firing drive system 530 in the handle assembly 500 is configured tobe operably coupled to a firing system 1300 that is operably supportedin the interchangeable surgical tool assembly 1000. The firing system1300 may include an intermediate firing shaft portion 1310 that isconfigured to be axially moved in the distal and proximal directions inresponse to corresponding firing motions applied thereto by the firingdrive system 530. See FIG. 4. As shown in FIG. 5, a proximal end 1312 ofthe intermediate firing shaft portion 1310 has a firing shaft attachmentlug 1314 formed thereon that is configured to be seated into anattachment cradle 544 (FIG. 3) that is on the distal end of thelongitudinally movable drive member 540 of the firing drive system 530within the handle assembly 500. Such arrangement facilitates the axialmovement of the intermediate firing shaft portion 1310 upon actuation ofthe firing drive system 530. In the illustrated example, theintermediate firing shaft portion 1310 is configured for attachment to adistal cutting portion or knife bar 1320. As shown in FIG. 4, the knifebar 1320 is connected to a firing member or knife member 1330. The knifemember 1330 comprises a knife body 1332 that operably supports a tissuecutting blade 1334 thereon. The knife body 1332 may further includeanvil engagement tabs or features 1336 and channel engagement featuresor a foot 1338 (FIG. 8). The anvil engagement features 1336 may serve toapply additional closure motions to the anvil 1810 as the knife member1330 is advanced distally through the end effector 1500.

In the illustrated example, the surgical end effector 1500 isselectively articulatable about the articulation axis AA by anarticulation system 1360. In one form, the articulation system 1360includes proximal articulation driver 1370 that is pivotally coupled toan articulation link 1380. As can be most particularly seen in FIG. 4,an offset attachment lug 1373 is formed on a distal end 1372 of theproximal articulation driver 1370. A pivot hole 1374 is formed in theoffset attachment lug 1373 and is configured to pivotally receivetherein a proximal link pin 1382 formed on the proximal end 1381 of thearticulation link 1380. A distal end 1383 of the articulation link 1380includes a pivot hole 1384 that is configured to pivotally receivetherein a channel pin 1618 formed on the proximal end portion 1610 ofthe elongate channel 1602. Thus, axial movement of proximal articulationdriver 1370 will thereby apply articulation motions to the elongatechannel 1602 to thereby cause the surgical end effector 1500 toarticulate about the articulation axis AA relative to the spine assembly1250. In various circumstances, the proximal articulation driver 1370can be held in position by an articulation lock 1390 when the proximalarticulation driver 1370 is not being moved in the proximal or distaldirections. Further details regarding an example form of articulationlock 1390 may be found in U.S. patent application Ser. No. 15/635,837entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLETO A FRAME, filed on Jun. 28, 2017, the entire disclosure of which ishereby incorporated by reference herein.

Further to the above, the interchangeable surgical tool assembly 1000can include a shifter assembly 1100 which can be configured toselectively and releasably couple the proximal articulation driver 1310to the firing system 1300. As illustrated in FIG. 5, for example, in oneform, the shifter assembly 1100 includes a lock collar, or lock sleeve1110, positioned around the intermediate firing shaft portion 1310 ofthe firing system 1300 wherein the lock sleeve 1110 can be rotatedbetween an engaged position in which the lock sleeve 1110 operablycouples the proximal articulation driver 1370 to the firing memberassembly 1300 and a disengaged position in which the proximalarticulation driver 1370 is not operably coupled to the firing memberassembly 1300. When lock sleeve 1110 is in its engaged position, distalmovement of the firing member assembly 1300 can move the proximalarticulation driver 1370 distally and, correspondingly, proximalmovement of the firing member assembly 1300 can move the proximalarticulation driver 1370 proximally. When lock sleeve 1110 is in itsdisengaged position, movement of the firing member assembly 1300 is nottransmitted to the proximal articulation driver 1370 and, as a result,the firing member assembly 1300 can move independently of the proximalarticulation driver 1370. In various circumstances, the proximalarticulation driver 1370 can be held in position by the articulationlock 1390 when the proximal articulation driver 1370 is not being movedin the proximal or distal directions by the firing member assembly 1300.

In the illustrated arrangement, the intermediate firing shaft portion1310 of the firing member assembly 1300 is formed with two opposed flatsides with a drive notch 1316 formed therein. See FIG. 5. As can also beseen in FIG. 5, the lock sleeve 1110 comprises a cylindrical, or an atleast substantially cylindrical, body that includes a longitudinalaperture that is configured to receive the intermediate firing shaftportion 1310 therethrough. The lock sleeve 1110 can comprisediametrically-opposed, inwardly-facing lock protrusions that, when thelock sleeve 1110 is in one position, are engagingly received withincorresponding portions of the drive notch 1316 in the intermediatefiring shaft portion 1310 and, when in another position, are notreceived within the drive notch 1316 to thereby permit relative axialmotion between the lock sleeve 1110 and the intermediate firing shaft1310. As can be further seen in FIG. 5, the lock sleeve 1110 furtherincludes a lock member 1112 that is sized to be movably received withina notch 1375 in a proximal end of the proximal articulation driver 1370.Such arrangement permits the lock sleeve 1110 to slightly rotate intoand out of engagement with the intermediate firing shaft portion 1310while remaining in position for engagement or in engagement with thenotch 1375 in the proximal articulation driver 1370. For example, whenthe lock sleeve 1110 is in its engaged position, the lock protrusionsare positioned within the drive notch 1316 in the intermediate firingshaft portion 1310 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member assembly 1300 tothe lock sleeve 1110. Such axial pushing or pulling motion is thentransmitted from the lock sleeve 1110 to the proximal articulationdriver 1370 to thereby articulate the surgical end effector 1500. Ineffect, the firing member assembly 1300, the lock sleeve 1110, and theproximal articulation driver 1370 will move together when the locksleeve 1110 is in its engaged (articulation) position. On the otherhand, when the lock sleeve 1110 is in its disengaged position, the lockprotrusions are not received within the drive notch 1316 in theintermediate firing shaft portion 1310 and, as a result, a distalpushing force and/or a proximal pulling force may not be transmittedfrom the firing member assembly 1300 to the lock sleeve 1110 (and theproximal articulation driver 1370).

In the illustrated example, relative movement of the lock sleeve 1110between its engaged and disengaged positions may be controlled by theshifter assembly 1100 that interfaces with the proximal closure tube1910. Still referring to FIG. 5, the shifter assembly 1100 furtherincludes a shifter key 1120 that is configured to be slidably receivedwithin a key groove formed in the outer perimeter of the lock sleeve1110. Such arrangement enables the shifter key 1120 to move axially withrespect to the lock sleeve 1110. As discussed in further detail in U.S.patent application Ser. No. 15/635,631 entitled SURGICAL INSTRUMENT WITHAXIALLY MOVABLE CLOSURE MEMBER, filed on Jun. 28, 2017, the entiredisclosure of which is hereby incorporated by reference herein, aportion of the shifter key 1120 is configured to cammingly interact witha cam opening (not shown) in the proximal closure tube portion 1910.Also in the illustrated example, the shifter assembly 1100 furtherincludes a switch drum 1130 that is rotatably received on a proximal endportion of the proximal closure tube portion 1910. A portion of theshifter key 1120 extends through an axial slot segment in the switchdrum 1130 and is movably received within an arcuate slot segment in theswitch drum 1130. A switch drum torsion spring 1132 is mounted on theswitch drum 1130 and engages a portion of the nozzle assembly 1240 toapply a torsional bias or rotation which serves to rotate the switchdrum 1130 until the portion of the shifter key 1120 reaches an endportion of the cam opening in the proximal closure tube portion 1910.When in this position, the switch drum 1130 may provide a torsional biasto the shifter key 1120 which thereby causes the lock sleeve 1110 torotate into its engaged position with the intermediate firing shaftportion 1310. This position also corresponds to the unactuatedconfiguration of the proximal closure tube 1910 (and distal closure tubesegment 1930).

In one arrangement, for example, when the proximal closure tube 1910 isin an unactuated configuration (anvil 1810 is in an open position spacedaway from the cartridge mounted in the elongate channel 1602) actuationof the intermediate firing shaft portion 1310 will result in the axialmovement of the proximal articulation driver 1370 to facilitatearticulation of the end effector 1500. Once the user has articulated thesurgical end effector 1500 to a desired orientation, the user may thenactuate the proximal closure tube portion 1910. Actuation of theproximal closure tube portion 1910 will result in the distal travel ofthe distal closure tube segment 1930 to ultimately apply a closingmotion to the anvil 1810. This distal travel of the proximal closuretube portion 1910 will result in the cam opening therein camminglyinteracting with a cam portion of the shifter key 1120 to thereby causethe shifter key 1120 to rotate the lock sleeve 1110 in an actuationdirection. Such rotation of the lock sleeve 1110 will result in thedisengagement of the lock protrusions from the drive notch 1316 in theintermediate firing shaft portion 1310. When in such configuration, thefiring drive system 530 may be actuated to actuate the intermediatefiring shaft portion 1310 without actuating the proximal articulationdriver 1370. Further details concerning the operation of the switch drum1130 and lock sleeve 1110, as well as alternative articulation andfiring drive arrangements that may be employed with the variousinterchangeable surgical tool assemblies described herein, may be foundin U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, and U.S. patent applicationSer. No. 15/019,196, the entire disclosures of which are herebyincorporated by reference herein.

As also illustrated in FIGS. 5 and 15, the interchangeable surgical toolassembly 1000 can comprise a slip ring assembly 1150 which can beconfigured to conduct electrical power to and/or from the surgical endeffector 1500 and/or communicate signals to and/or from the surgical endeffector 1500, back to an onboard circuit board 1152, while facilitatingrotational travel of the shaft and end effector 1500 about the shaftaxis SA relative to the tool chassis 1210 by rotating the nozzleassembly 1240. As shown in FIG. 15, in at least one arrangement, theonboard circuit board 1152 includes an onboard connector 1154 that isconfigured to interface with a housing connector 562 (FIG. 9)communicating with a microprocessor 560 that is supported in the handleassembly 500 or robotic system controller, for example. The slip ringassembly 1150 is configured to interface with a proximal connector 1153that interfaces with the onboard circuit board 1152. Further detailsconcerning the slip ring assembly 1150 and associated connectors may befound in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, and U.S. patent applicationSer. No. 15/019,196 which have each been herein incorporated byreference in their respective entirety as well as in U.S. patentapplication Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, now U.S. Patent Application Publication No.2014/0263552, which is hereby incorporated by reference herein in itsentirety.

An example version of the interchangeable surgical tool assembly 1000disclosed herein may be employed in connection with a standard(mechanical) surgical fastener cartridge 1400 or a cartridge 1700 thatis configured to facilitate cutting of tissue with the knife member andseal the cut tissue using radio frequency (RF) energy. Turning again toFIG. 4, a conventional or standard mechanical-type cartridge 1400 isdepicted. Such cartridge arrangements are known and may comprise acartridge body 1402 that is sized and shaped to be removably receivedand supported in the elongate channel 1602. For example, the cartridgebody 1402 may be configured to be removably retained in snap engagementwith the elongate channel 1602. The cartridge body 1402 includes anelongate slot 1404 to accommodate axial travel of the knife member 1330therethrough. The cartridge body 1402 operably supports therein aplurality of staple drivers (not shown) that are aligned in rows on eachside of the centrally disposed elongate slot 1404. The drivers areassociated with corresponding staple/fastener pockets 1412 that openthrough the upper deck surface 1410 of the cartridge body 1402. Each ofthe staple drivers supports one or more surgical staple or fastener (notshown) thereon. A sled assembly 1420 is supported within a proximal endof the cartridge body 1402 and is located proximal to the drivers andfasteners in a starting position when the cartridge 1400 is new andunfired. The sled assembly 1420 includes a plurality of sloped orwedge-shaped cams 1422 wherein each cam 1422 corresponds to a particularline of fasteners or drivers located on a side of the slot 1404. Thesled assembly 1420 is configured to be contacted and driven by the knifemember 1330 as the knife member is driven distally through the tissuethat is clamped between the anvil and the cartridge deck surface 1410.As the drivers are driven upward toward the cartridge deck surface 1410,the fastener(s) supported thereon are driven out of their staple pockets1412 and through the tissue that is clamped between anvil and thecartridge.

Still referring to FIG. 4, the anvil 1810 in at least one form includesan anvil mounting portion 1820 that has a pair of anvil trunnions 1822protruding laterally therefrom to be pivotally received in correspondingtrunnion cradles 1614 formed in the upstanding walls 1622 of theproximal end portion 1610 of the elongate channel 1602. The anviltrunnions 1822 are pivotally retained in their corresponding trunnioncradle 1614 by the channel cap or anvil retainer 1630. The anvilmounting portion 1820 is movably or pivotably supported on the elongatechannel 1602 for selective pivotal travel relative thereto about a fixedanvil pivot axis that is transverse to the shaft axis SA. As shown inFIGS. 6 and 7, in at least one form, the anvil 1810 includes an anvilbody portion 1812 that is fabricated from an electrically conductivemetal material for example and has a staple forming undersurface 1813that has a series of fastener forming pockets 1814 formed therein oneach side of a centrally disposed anvil slot 1815 that is configured toslidably accommodate the knife member 1330 therein. The anvil slot 1815opens into an upper opening 1816 that extends longitudinally through theanvil body 1812 to accommodate the anvil engagement features 1336 on theknife member 1330 during firing. When a conventional mechanical surgicalstaple/fastener cartridge 1400 is installed in the elongate channel1602, the staples/fasteners are driven through the tissue T and intoforming contact with the corresponding fastener forming pockets 1814.The anvil body 1812 may have an opening in the upper portion thereof tofacilitate ease of installation for example. An anvil cap 1818 may beinserted therein and welded to the anvil body 1812 to enclose theopening and improve the overall stiffness of the anvil body 1812. Asshown in FIG. 7, to facilitate use of the end effector 1500 inconnection with RF cartridges 1700, the tissue facing segments 1817 ofthe fastener forming undersurface 1813 may have electrically insulativematerial 1819 thereon.

In the illustrated arrangement, the interchangeable surgical toolassembly 1000 is configured with a firing member lockout system,generally designated as 1640. See FIG. 8. As shown in FIG. 8, theelongate channel 1602 includes a bottom surface or bottom portion 1620that has two upstanding side walls 1622 protruding therefrom. Acentrally disposed longitudinal channel slot 1624 is formed through thebottom portion 1620 to facilitate the axial travel of the knife member1330 therethrough. The channel slot 1624 opens into a longitudinalpassage 1626 that accommodates the channel engagement feature or foot1338 on the knife member 1330. The passage 1626 serves to define twoinwardly extending ledge portions 1628 that serve to engagecorresponding portions of the channel engagement feature or foot 1338.The firing member lockout system 1640 includes proximal openings 1642located on each side of the channel slot 1624 that are each configuredto receive corresponding portions of the channel engagement feature orfoot 1338 when the knife member 1330 is in a starting position. A knifelockout spring 1650 is supported in the proximal end 1610 of theelongate channel 1602 and serves to bias the knife member 1330 downward.As shown in FIG. 8, the knife lockout spring 1650 includes two distallyending spring arms 1652 that are configured to engage correspondingcentral channel engagement features 1337 on the knife body 1332. Thespring arms 1652 are configured to bias the central channel engagementfeatures 1337 downward. Thus, when in the starting (unfired position),the knife member 1330 is biased downward such that the channelengagement features or foot 1338 is received within the correspondingproximal openings 1642 in the elongate 1602 channel. When in that lockedposition, if one were to attempt to distally advance the knife 1330, thecentral channel engagement features 1137 and/or foot 1338 would engageupstanding ledges 1654 on the elongate channel 1602 (FIGS. 8 and 11) andthe knife 1330 could not be fired.

Still referring to FIG. 8, the firing member lockout system 1640 alsoincludes an unlocking assembly 1660 formed or supported on a distal endof the firing member body 1332. The unlocking assembly 1660 includes adistally extending ledge 1662 that is configured to engage an unlockingfeature 1426 formed on the sled assembly 1420 when the sled assembly1420 is in its starting position in an unfired surgical staple cartridge1400. Thus, when an unfired surgical staple cartridge 1400 is properlyinstalled in the elongate channel 1602, the ledge 1662 on the unlockingassembly 1660 contacts the unlocking feature 1426 on the sled assembly1420 which serves to bias the knife member 1330 upward such that thecentral channel engagement features 1137 and/or foot 1338 clear theupstanding ledges 1654 in the channel bottom 1620 to facilitate axialpassage of the knife member 1330 through the elongate channel 1602. If apartially fired cartridge 1400 is unwittingly installed in the elongatechannel, the sled assembly 1420 will not be in the starting position andthe knife member 1330 will remain in the locked position.

Attachment of the interchangeable surgical tool assembly 1000 to thehandle assembly 500 will now be described with reference to FIGS. 3 and9. To commence the coupling process, the clinician may position the toolchassis 1210 of the interchangeable surgical tool assembly 1000 above oradjacent to the distal end of the handle frame 506 such that taperedattachment portions 1212 formed on the tool chassis 1210 are alignedwith dovetail slots 507 in the handle frame 506. The clinician may thenmove the surgical tool assembly 1000 along an installation axis IA thatis perpendicular to the shaft axis SA to seat the tapered attachmentportions 1212 in “operable engagement” with the corresponding dovetailreceiving slots 507 in the distal end of the handle frame 506. In doingso, the firing shaft attachment lug 1314 on the intermediate firingshaft portion 1310 will also be seated in the cradle 544 in thelongitudinally movable drive member 540 within the handle assembly 500and the portions of a pin 516 on a closure link 514 will be seated inthe corresponding hooks 1917 in the closure shuttle 1914. As usedherein, the term “operable engagement” in the context of two componentsmeans that the two components are sufficiently engaged with each otherso that upon application of an actuation motion thereto, the componentsmay carry out their intended action, function and/or procedure. Alsoduring this process, the onboard connector 1154 on the surgical toolassembly 1000 is coupled to the housing connector 562 that communicateswith the microprocessor 560 that is supported in the handle assembly 500or robotic system controller, for example.

During a typical surgical procedure, the clinician may introduce thesurgical end effector 1500 into the surgical site through a trocar orother opening in the patient to access the target tissue. When doing so,the clinician typically axially aligns the surgical end effector 1500along the shaft axis SA (unarticulated state). Once the surgical endeffector 1500 has passed through the trocar port, for example, theclinician may need to articulate the end effector 1500 to advantageouslyposition it adjacent the target tissue. This is prior to closing theanvil 1810 onto the target tissue, so the closure drive system 510 wouldremain unactuated. When in this position, actuation of the firing drivesystem 530 will result in the application of articulation motions to theproximal articulation driver 1370. Once the end effector 1500 hasattained the desired articulated position, the firing drive system 530is deactivated and the articulation lock 1390 may retain the surgicalend effector 1500 in the articulated position. The clinician may thenactuate the closure drive system 510 to close the anvil 1810 onto thetarget tissue. Such actuation of the closure drive system 510 may alsoresult in the shifter assembly 1100 delinking the proximal articulationdriver 1370 from the intermediate firing shaft portion 1310. Thus, oncethe target tissue has been captured in the surgical end effector 1500,the clinician may once again actuate the firing drive system 530 toaxially advance the firing member 1330 through the surgicalstaple/fastener cartridge 1400 or RF cartridge 1700 to cut the clampedtissue and fire the staples/fasteners into the cut tissue T. Otherclosure and firing drive arrangements, actuator arrangements (bothhandheld, manual and automated or robotic) may also be employed tocontrol the axial movement of the closure system components, thearticulation system components and/or the firing system components ofthe surgical tool assembly 1000 without departing from the scope of thepresent disclosure.

As indicated above, the surgical tool assembly 1000 is configured to beused in connection with conventional mechanical surgical staple/fastenercartridges 1400 as well as with RF cartridges 1700. In at least oneform, the RF cartridge 1700 may facilitate mechanical cutting of tissuethat is clamped between the anvil 1810 and the RF cartridge 1700 withthe knife member 1330 while coagulating electrical current is deliveredto the tissue in the current path. Alternative arrangements formechanically cutting and coagulating tissue using electrical current aredisclosed in, for example, U.S. Pat. Nos. 5,403,312; 7,780,663 and U.S.patent application Ser. No. 15/142,609, entitled ELECTROSURGICALINSTRUMENT WITH ELECTRICALLY CONDUCTIVE GAP SETTING AND TISSUE ENGAGINGMEMBERS, the entire disclosures of each said references beingincorporated by reference herein. Such instruments, may, for example,improve hemostasis, reduce surgical complexity as well as operating roomtime.

As shown in FIGS. 10-12, in at least one arrangement, the RF surgicalcartridge 1700 includes a cartridge body 1710 that is sized and shapedto be removably received and supported in the elongate channel 1602. Forexample, the cartridge body 1710 may be configured to be removablyretained in snap engagement with the elongate channel 1602. In variousarrangements, the cartridge body 1710 may be fabricated from a polymermaterial, such as, for example, an engineering thermoplastic such as theliquid crystal polymer (LCP) VECTRA™ and the elongate channel 1602 maybe fabricated from metal. In at least one aspect, the cartridge body1710 includes a centrally disposed elongate slot 1712 that extendslongitudinally through the cartridge body to accommodate longitudinaltravel of the knife 1330 therethrough. As shown in FIGS. 10 and 11, apair of lockout engagement tails 1714 extend proximally from thecartridge body 1710. Each lockout engagement tail 1714 has a lockout pad1716 formed on the underside thereof that are sized to be receivedwithin a corresponding proximal opening portion 1642 in the channelbottom 1620. Thus, when the cartridge 1700 is properly installed in theelongate channel 1602, the lockout engagement tails 1714 cover theopenings 1642 and ledges 1654 to retain the knife 1330 in an unlockedposition ready for firing.

Turning now to FIGS. 10-13, in the illustrated example, the cartridgebody 1710 is formed with a centrally disposed raised electrode pad 1720.As can be most particularly seen in FIG. 6, the elongate slot 1712extends through the center of the electrode pad 1720 and serves todivide the pad 1720 into a left pad segment 1720L and a right padsegment 1720R. A right flexible circuit assembly 1730R is attached tothe right pad segment 1720R and a left flexible circuit assembly 1730Lis attached to the left pad segment 1720L. In at least one arrangementfor example, the right flexible circuit 1730R comprises a plurality ofelectrical conductors 1732R that may include, for example, widerelectrical conductors/conductors for RF purposes and thinner electricalconductors for conventional stapling purposes that are supported orattached or embedded into a right insulator sheath/member 1734R that isattached to the right pad 1720R. In addition, the right flexible circuitassembly 1730R includes a “phase one”, proximal right electrode 1736Rand a “phase two” distal right electrode 1738R. Likewise, the leftflexible circuit assembly 1730L comprises a plurality of electricalconductors 1732L that may include, for example, wider electricalconductors/conductors for RF purposes and thinner electrical conductorsfor conventional stapling purposes that are supported or attached orembedded into a left insulator sheath/member 1734L that is attached tothe left pad 1720L. In addition, the left flexible circuit assembly1730L includes a “phase one”, proximal left electrode 1736L and a “phasetwo” distal left electrode 1738L. The left and right electricalconductors 1732L, 1732R are attached to a distal micro-chip 1740 mountedto the distal end portion of the cartridge body 1710. In onearrangement, for example, each of the right and left flexible circuits1730R, 1730L may have an overall width “CW” of approximately 0.025inches and each of the electrodes 1736R, 1736L, 1738R, 1738R has a width“EW” of approximately 0.010 inches for example. See FIG. 13. However,other widths/sizes are contemplated and may be employed in alternativeaspects.

In at least one arrangement, RF energy is supplied to the surgical toolassembly 1000 by a conventional RF generator 400 through a supply lead402. In at least one arrangement, the supply lead 402 includes a maleplug assembly 406 that is configured to be plugged into correspondingfemale connectors 410 that are attached to a segmented RF circuit 1160on the an onboard circuit board 1152. See FIG. 15. Such arrangementfacilitates rotational travel of the shaft and end effector 1500 aboutthe shaft axis SA relative to the tool chassis 1210 by rotating thenozzle assembly 1240 without winding up the supply lead 402 from thegenerator 400. An onboard on/off power switch 420 is supported on thelatch assembly 1280 and tool chassis 1210 for turning the RF generatoron and off. When the tool assembly 1000 is operably coupled to thehandle assembly 500 or robotic system, the onboard segmented RF circuit1160 communicates with the microprocessor 560 through the connectors1154 and 562. As shown in FIG. 1, the handle assembly 500 may alsoinclude a display screen 430 for viewing information about the progressof sealing, stapling, knife location, status of the cartridge, tissue,temperature, etc. As can also be seen in FIG. 15, the slip ring assembly1150 interfaces with a distal connector 1162 that includes a flexibleshaft circuit strip or assembly 1164 that may include a plurality ofnarrow electrical conductors 1166 for stapling related activities andwider electrical conductors 1168 used for RF purposes. As shown in FIGS.14 and 15, the flexible shaft circuit strip 1164 is centrally supportedbetween the laminated plates or bars 1322 that form the knife bar 1320.Such arrangement facilitates sufficient flexing of the knife bar 1320and flexible shaft circuit strip 1164 during articulation of the endeffector 1500 while remaining sufficiently stiff so as to enable theknife member 1330 to be distally advanced through the clamped tissue.

Turning again to FIG. 10, in at least one illustrated arrangement, theelongate channel 1602 includes a channel circuit 1670 supported in arecess 1621 that extends from the proximal end 1610 of the elongatechannel 1602 to a distal location 1623 in the elongate channel bottomportion 1620. The channel circuit 1670 includes a proximal contactportion 1672 that contacts a distal contact portion 1169 of the flexibleshaft circuit strip 1164 for electrical contact therewith. A distal end1674 of the channel circuit 1670 is received within a corresponding wallrecess 1625 formed in one of the channel walls 1622 and is folded overand attached to an upper edge 1627 of the channel wall 1622. A series ofcorresponding exposed contacts 1676 are provided in the distal end 1674of the channel circuit 1670 As shown in FIG. 10. As can also be seen inFIG. 10, an end 1752 of a flexible cartridge circuit 1750 is attached tothe distal micro-chip 1740 and is affixed to the distal end portion ofthe cartridge body 1710. Another end 1754 is folded over the edge of thecartridge deck surface 1711 and includes exposed contacts 1756configured to make electrical contact with the exposed contacts 1676 ofthe channel circuit 1670. Thus, when the RF cartridge 1700 is installedin the elongate channel 1602, the electrodes as well as the distalmicro-chip 1740 are powered and communicate with the onboard circuitboard 1152 through contact between the flexible cartridge circuit 1750,the flexible channel circuit 1670, the flexible shaft circuit 1164 andthe slip ring assembly 1150.

FIGS. 16A-16B is a block diagram of a control circuit 700 of thesurgical instrument 10 of FIG. 1 spanning two drawing sheets accordingto one aspect of this disclosure. Referring primarily to FIGS. 16A-16B,a handle assembly 702 may include a motor 714 which can be controlled bya motor driver 715 and can be employed by the firing system of thesurgical instrument 10. In various forms, the motor 714 may be a DCbrushed driving motor having a maximum rotational speed of approximately25,000 RPM. In other arrangements, the motor 714 may include a brushlessmotor, a cordless motor, a synchronous motor, a stepper motor, or anyother suitable electric motor. The motor driver 715 may comprise anH-Bridge driver comprising field-effect transistors (FETs) 719, forexample. The motor 714 can be powered by the power assembly 706releasably mounted to the handle assembly 500 for supplying controlpower to the surgical instrument 10. The power assembly 706 may comprisea battery which may include a number of battery cells connected inseries that can be used as the power source to power the surgicalinstrument 10. In certain circumstances, the battery cells of the powerassembly 706 may be replaceable and/or rechargeable. In at least oneexample, the battery cells can be Lithium-Ion batteries which can beseparably couplable to the power assembly 706.

The shaft assembly 704 may include a shaft assembly controller 722 whichcan communicate with a safety controller and power management controller716 through an interface while the shaft assembly 704 and the powerassembly 706 are coupled to the handle assembly 702. For example, theinterface may comprise a first interface portion 725 which may includeone or more electric connectors for coupling engagement withcorresponding shaft assembly electric connectors and a second interfaceportion 727 which may include one or more electric connectors forcoupling engagement with corresponding power assembly electricconnectors to permit electrical communication between the shaft assemblycontroller 722 and the power management controller 716 while the shaftassembly 704 and the power assembly 706 are coupled to the handleassembly 702. One or more communication signals can be transmittedthrough the interface to communicate one or more of the powerrequirements of the attached interchangeable shaft assembly 704 to thepower management controller 716. In response, the power managementcontroller may modulate the power output of the battery of the powerassembly 706, as described below in greater detail, in accordance withthe power requirements of the attached shaft assembly 704. Theconnectors may comprise switches which can be activated after mechanicalcoupling engagement of the handle assembly 702 to the shaft assembly 704and/or to the power assembly 706 to allow electrical communicationbetween the shaft assembly controller 722 and the power managementcontroller 716.

The interface can facilitate transmission of the one or morecommunication signals between the power management controller 716 andthe shaft assembly controller 722 by routing such communication signalsthrough a main controller 717 residing in the handle assembly 702, forexample. In other circumstances, the interface can facilitate a directline of communication between the power management controller 716 andthe shaft assembly controller 722 through the handle assembly 702 whilethe shaft assembly 704 and the power assembly 706 are coupled to thehandle assembly 702.

The main controller 717 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments. In one aspect, the main controller 717 may be anLM4F230H5QR ARM Cortex-M4F Processor Core, available from TexasInstruments, for example, comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules, one or more quadrature encoder inputs (QEI)analog, one or more 12-bit Analog-to-Digital Converters (ADC) with 12analog input channels, details of which are available for the productdatasheet.

The safety controller may be a safety controller platform comprising twocontroller-based families such as TMS570 and RM4x known under the tradename Hercules ARM Cortex R4, also by Texas Instruments. The safetycontroller may be configured specifically for IEC 61508 and ISO 26262safety critical applications, among others, to provide advancedintegrated safety features while delivering scalable performance,connectivity, and memory options.

The power assembly 706 may include a power management circuit which maycomprise the power management controller 716, a power modulator 738, anda current sense circuit 736. The power management circuit can beconfigured to modulate power output of the battery based on the powerrequirements of the shaft assembly 704 while the shaft assembly 704 andthe power assembly 706 are coupled to the handle assembly 702. The powermanagement controller 716 can be programmed to control the powermodulator 738 of the power output of the power assembly 706 and thecurrent sense circuit 736 can be employed to monitor power output of thepower assembly 706 to provide feedback to the power managementcontroller 716 about the power output of the battery so that the powermanagement controller 716 may adjust the power output of the powerassembly 706 to maintain a desired output. The power managementcontroller 716 and/or the shaft assembly controller 722 each maycomprise one or more processors and/or memory units which may store anumber of software modules.

The surgical instrument 10 (FIGS. 1-5) may comprise an output device 742which may include devices for providing a sensory feedback to a user.Such devices may comprise, for example, visual feedback devices (e.g.,an LCD display screen, LED indicators), audio feedback devices (e.g., aspeaker, a buzzer) or tactile feedback devices (e.g., haptic actuators).In certain circumstances, the output device 742 may comprise a display743 which may be included in the handle assembly 702. The shaft assemblycontroller 722 and/or the power management controller 716 can providefeedback to a user of the surgical instrument 10 through the outputdevice 742. The interface can be configured to connect the shaftassembly controller 722 and/or the power management controller 716 tothe output device 742. The output device 742 can instead be integratedwith the power assembly 706. In such circumstances, communicationbetween the output device 742 and the shaft assembly controller 722 maybe accomplished through the interface while the shaft assembly 704 iscoupled to the handle assembly 702.

The control circuit 700 comprises circuit segments configured to controloperations of the powered surgical instrument 10. A safety controllersegment (Segment 1) comprises a safety controller and the maincontroller 717 segment (Segment 2). The safety controller and/or themain controller 717 are configured to interact with one or moreadditional circuit segments such as an acceleration segment, a displaysegment, a shaft segment, an encoder segment, a motor segment, and apower segment. Each of the circuit segments may be coupled to the safetycontroller and/or the main controller 717. The main controller 717 isalso coupled to a flash memory. The main controller 717 also comprises aserial communication interface. The main controller 717 comprises aplurality of inputs coupled to, for example, one or more circuitsegments, a battery, and/or a plurality of switches. The segmentedcircuit may be implemented by any suitable circuit, such as, forexample, a printed circuit board assembly (PCBA) within the poweredsurgical instrument 10. It should be understood that the term processoras used herein includes any microprocessor, processors, controller,controllers, or other basic computing device that incorporates thefunctions of a computer's central processing unit (CPU) on an integratedcircuit or at most a few integrated circuits. The main controller 717 isa multipurpose, programmable device that accepts digital data as input,processes it according to instructions stored in its memory, andprovides results as output. It is an example of sequential digitallogic, as it has internal memory. The control circuit 700 can beconfigured to implement one or more of the processes described herein.

The acceleration segment (Segment 3) comprises an accelerometer. Theaccelerometer is configured to detect movement or acceleration of thepowered surgical instrument 10. Input from the accelerometer may be usedto transition to and from a sleep mode, identify an orientation of thepowered surgical instrument, and/or identify when the surgicalinstrument has been dropped. In some examples, the acceleration segmentis coupled to the safety controller and/or the main controller 717.

The display segment (Segment 4) comprises a display connector coupled tothe main controller 717. The display connector couples the maincontroller 717 to a display through one or more integrated circuitdrivers of the display. The integrated circuit drivers of the displaymay be integrated with the display and/or may be located separately fromthe display. The display may comprise any suitable display, such as, forexample, an organic light-emitting diode (OLED) display, aliquid-crystal display (LCD), and/or any other suitable display. In someexamples, the display segment is coupled to the safety controller.

The shaft segment (Segment 5) comprises controls for an interchangeableshaft assembly 500 coupled to the surgical instrument 10 (FIGS. 1-5)and/or one or more controls for an end effector 1500 coupled to theinterchangeable shaft assembly 500. The shaft segment comprises a shaftconnector configured to couple the main controller 717 to a shaft PCBA.The shaft PCBA comprises a low-power microcontroller with aferroelectric random access memory (FRAM), an articulation switch, ashaft release Hall effect switch, and a shaft PCBA EEPROM. The shaftPCBA EEPROM comprises one or more parameters, routines, and/or programsspecific to the interchangeable shaft assembly 500 and/or the shaftPCBA. The shaft PCBA may be coupled to the interchangeable shaftassembly 500 and/or integral with the surgical instrument 10. In someexamples, the shaft segment comprises a second shaft EEPROM. The secondshaft EEPROM comprises a plurality of algorithms, routines, parameters,and/or other data corresponding to one or more shaft assemblies 500and/or end effectors 1500 that may be interfaced with the poweredsurgical instrument 10.

The position encoder segment (Segment 6) comprises one or more magneticangle rotary position encoders. The one or more magnetic angle rotaryposition encoders are configured to identify the rotational position ofthe motor 714, an interchangeable shaft assembly 500, and/or an endeffector 1500 of the surgical instrument 10 (FIGS. 1-5). In someexamples, the magnetic angle rotary position encoders may be coupled tothe safety controller and/or the main controller 717.

The motor circuit segment (Segment 7) comprises a motor 714 configuredto control movements of the powered surgical instrument 10 (FIGS. 1-5).The motor 714 is coupled to the main microcontroller processor 717 by anH-bridge driver comprising one or more H-bridge field-effect transistors(FETs) and a motor controller. The H-bridge driver is also coupled tothe safety controller. A motor current sensor is coupled in series withthe motor to measure the current draw of the motor. The motor currentsensor is in signal communication with the main controller 717 and/orthe safety controller. In some examples, the motor 714 is coupled to amotor electromagnetic interference (EMI) filter.

The motor controller controls a first motor flag and a second motor flagto indicate the status and position of the motor 714 to the maincontroller 717. The main controller 717 provides a pulse-widthmodulation (PWM) high signal, a PWM low signal, a direction signal, asynchronize signal, and a motor reset signal to the motor controllerthrough a buffer. The power segment is configured to provide a segmentvoltage to each of the circuit segments.

The power segment (Segment 8) comprises a battery coupled to the safetycontroller, the main controller 717, and additional circuit segments.The battery is coupled to the segmented circuit by a battery connectorand a current sensor. The current sensor is configured to measure thetotal current draw of the segmented circuit. In some examples, one ormore voltage converters are configured to provide predetermined voltagevalues to one or more circuit segments. For example, in some examples,the segmented circuit may comprise 3.3V voltage converters and/or 5Vvoltage converters. A boost converter is configured to provide a boostvoltage up to a predetermined amount, such as, for example, up to 13V.The boost converter is configured to provide additional voltage and/orcurrent during power intensive operations and prevent brownout orlow-power conditions.

A plurality of switches are coupled to the safety controller and/or themain controller 717. The switches may be configured to controloperations of the surgical instrument 10 (FIGS. 1-5), of the segmentedcircuit, and/or indicate a status of the surgical instrument 10. Abail-out door switch and Hall effect switch for bailout are configuredto indicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch, aleft side articulation right switch, a left side articulation centerswitch, a right side articulation left switch, a right side articulationright switch, and a right side articulation center switch are configuredto control articulation of an interchangeable shaft assembly 500 (FIGS.1 and 3) and/or the end effector 300 (FIGS. 1 and 4). A left sidereverse switch and a right side reverse switch are coupled to the maincontroller 717. The left side switches comprising the left sidearticulation left switch, the left side articulation right switch, theleft side articulation center switch, and the left side reverse switchare coupled to the main controller 717 by a left flex connector. Theright side switches comprising the right side articulation left switch,the right side articulation right switch, the right side articulationcenter switch, and the right side reverse switch are coupled to the maincontroller 717 by a right flex connector. A firing switch, a clamprelease switch, and a shaft engaged switch are coupled to the maincontroller 717.

Any suitable mechanical, electromechanical, or solid state switches maybe employed to implement the plurality of switches, in any combination.For example, the switches may be limit switches operated by the motionof components associated with the surgical instrument 10 (FIGS. 1-5) orthe presence of an object. Such switches may be employed to controlvarious functions associated with the surgical instrument 10. A limitswitch is an electromechanical device that consists of an actuatormechanically linked to a set of contacts. When an object comes intocontact with the actuator, the device operates the contacts to make orbreak an electrical connection. Limit switches are used in a variety ofapplications and environments because of their ruggedness, ease ofinstallation, and reliability of operation. They can determine thepresence or absence, passing, positioning, and end of travel of anobject. In other implementations, the switches may be solid stateswitches that operate under the influence of a magnetic field such asHall-effect devices, magneto-resistive (MR) devices, giantmagneto-resistive (GMR) devices, magnetometers, among others. In otherimplementations, the switches may be solid state switches that operateunder the influence of light, such as optical sensors, infrared sensors,ultraviolet sensors, among others. Still, the switches may be solidstate devices such as transistors (e.g., FET, Junction-FET, metal-oxidesemiconductor-FET (MOSFET), bipolar, and the like). Other switches mayinclude electrical conductorless switches, ultrasonic switches,accelerometers, inertial sensors, among others.

FIG. 17 is another block diagram of the control circuit 700 of thesurgical instrument of FIG. 1 illustrating interfaces between the handleassembly 702 and the power assembly 706 and between the handle assembly702 and the interchangeable shaft assembly 704 according to one aspectof this disclosure. The handle assembly 702 may comprise a maincontroller 717, a shaft assembly connector 726 and a power assemblyconnector 730. The power assembly 706 may include a power assemblyconnector 732, a power management circuit 734 that may comprise thepower management controller 716, a power modulator 738, and a currentsense circuit 736. The shaft assembly connectors 730, 732 form aninterface 727. The power management circuit 734 can be configured tomodulate power output of the battery 707 based on the power requirementsof the interchangeable shaft assembly 704 while the interchangeableshaft assembly 704 and the power assembly 706 are coupled to the handleassembly 702. The power management controller 716 can be programmed tocontrol the power modulator 738 of the power output of the powerassembly 706 and the current sense circuit 736 can be employed tomonitor power output of the power assembly 706 to provide feedback tothe power management controller 716 about the power output of thebattery 707 so that the power management controller 716 may adjust thepower output of the power assembly 706 to maintain a desired output. Theshaft assembly 704 comprises a shaft processor 719 coupled to anon-volatile memory 721 and shaft assembly connector 728 to electricallycouple the shaft assembly 704 to the handle assembly 702. The shaftassembly connectors 726, 728 form interface 725. The main controller717, the shaft processor 719, and/or the power management controller 716can be configured to implement one or more of the processes describedherein.

The surgical instrument 10 (FIGS. 1-5) may comprise an output device 742to a sensory feedback to a user. Such devices may comprise visualfeedback devices (e.g., an LCD display screen, LED indicators), audiofeedback devices (e.g., a speaker, a buzzer), or tactile feedbackdevices (e.g., haptic actuators). In certain circumstances, the outputdevice 742 may comprise a display 743 that may be included in the handleassembly 702. The shaft assembly controller 722 and/or the powermanagement controller 716 can provide feedback to a user of the surgicalinstrument 10 through the output device 742. The interface 727 can beconfigured to connect the shaft assembly controller 722 and/or the powermanagement controller 716 to the output device 742. The output device742 can be integrated with the power assembly 706. Communication betweenthe output device 742 and the shaft assembly controller 722 may beaccomplished through the interface 725 while the interchangeable shaftassembly 704 is coupled to the handle assembly 702. Having described acontrol circuit 700 (FIGS. 16A-16B and 6) for controlling the operationof the surgical instrument 10 (FIGS. 1-5), the disclosure now turns tovarious configurations of the surgical instrument 10 (FIGS. 1-5) andcontrol circuit 700.

FIG. 18 is a schematic diagram of a surgical instrument 600 configuredto control various functions according to one aspect of this disclosure.In one aspect, the surgical instrument 600 is programmed to controldistal translation of a displacement member such as the I-beam 614. Thesurgical instrument 600 comprises an end effector 602 that may comprisean anvil 616, an I-beam 614, and a removable staple cartridge 618 whichmay be interchanged with an RF cartridge 609 (shown in dashed line). Theend effector 602, anvil 616, I-beam 614, staple cartridge 618, and RFcartridge 609 may be configured as described herein, for example, withrespect to FIGS. 1-15. For conciseness and clarity of disclosure,several aspects of the present disclosure may be described withreference to FIG. 18. It will be appreciated that the components shownschematically in FIG. 18 such as the control circuit 610, sensors 638,position sensor 634, end effector 602, I-beam 614, staple cartridge 618,RF cartridge 609, anvil 616, are described in connection with FIGS. 1-17of this disclosure.

Accordingly, the components represented schematically in FIG. 18 may bereadily substituted with the physical and functional equivalentcomponents described in connection with FIGS. 1-17. For example, in oneaspect, the control circuit 610 may be implemented as the controlcircuit 700 shown and described in connection with FIGS. 16-17. In oneaspect, the sensors 638 may be implemented as a limit switch,electromechanical device, solid state switches, Hall-effect devices,magneto-resistive (MR) devices, giant magneto-resistive (GMR) devices,magnetometers, among others. In other implementations, the sensors 638may be solid state switches that operate under the influence of light,such as optical sensors, infrared sensors, ultraviolet sensors, amongothers. Still, the switches may be solid state devices such astransistors (e.g., FET, Junction-FET, metal-oxide semiconductor-FET(MOSFET), bipolar, and the like). In other implementations, the sensors638 may include electrical conductorless switches, ultrasonic switches,accelerometers, inertial sensors, among others. In one aspect, theposition sensor 634 may be implemented as an absolute positioning systemcomprising a magnetic rotary absolute positioning system implemented asan AS5055EQFT single-chip magnetic rotary position sensor available fromAustria Microsystems, AG. The position sensor 634 may interface with thecontrol circuit 700 to provide an absolute positioning system. Theposition may include multiple Hall-effect elements located above amagnet and coupled to a CORDIC processor (for Coordinate RotationDigital Computer), also known as the digit-by-digit method and Volder'salgorithm, is provided to implement a simple and efficient algorithm tocalculate hyperbolic and trigonometric functions that require onlyaddition, subtraction, bitshift, and table lookup operations. In oneaspect, the end effector 602 may be implemented as surgical end effector1500 shown and described in connection with FIGS. 1, 2, and 4. In oneaspect, the I-beam 614 may be implemented as the knife member 1330comprising a knife body 1332 that operably supports a tissue cuttingblade 1334 thereon and may further include anvil engagement tabs orfeatures 1336 and channel engagement features or a foot 1338 as shownand described in connection with FIGS. 2-4, 8, 11 and 14. In one aspect,the staple cartridge 618 may be implemented as the standard (mechanical)surgical fastener cartridge 1400 shown and described in connection withFIG. 4. In one aspect, the RF cartridge 609 may be implemented as theradio frequency (RF) cartridge 1700 shown and described in connectionwith FIGS. 1, 2, 6, and 10-13. In one aspect, the anvil 616 may beimplemented the anvil 1810 shown and described in connection with FIGS.1, 2, 4, and 6. These and other sensors arrangements are described incommonly owned U.S. patent application Ser. No. 15/628,175, entitledTECHNIQUES FOR ADAPTIVE CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLINGAND CUTTING INSTRUMENT, which is incorporated herein by reference in itsentirety.

The position, movement, displacement, and/or translation of a linerdisplacement member, such as the I-beam 614, can be measured by anabsolute positioning system, sensor arrangement, and position sensorrepresented as position sensor 634. Because the I-beam 614 is coupled tothe longitudinally movable drive member 540, the position of the I-beam614 can be determined by measuring the position of the longitudinallymovable drive member 540 employing the position sensor 634. Accordingly,in the following description, the position, displacement, and/ortranslation of the I-beam 614 can be achieved by the position sensor 634as described herein. A control circuit 610, such as the control circuit700 described in FIGS. 16A and 16B, may be programmed to control thetranslation of the displacement member, such as the I-beam 614, asdescribed herein. The control circuit 610, in some examples, maycomprise one or more microcontrollers, microprocessors, or othersuitable processors for executing instructions that cause the processoror processors to control the displacement member, e.g., the I-beam 614,in the manner described. In one aspect, a timer/counter circuit 631provides an output signal, such as elapsed time or a digital count, tothe control circuit 610 to correlate the position of the I-beam 614 asdetermined by the position sensor 634 with the output of thetimer/counter circuit 631 such that the control circuit 610 candetermine the position of the I-beam 614 at a specific time (t) relativeto a starting position. The timer/counter circuit 631 may be configuredto measure elapsed time, count external evens, or time external events.

The control circuit 610 may generate a motor set point signal 622. Themotor set point signal 622 may be provided to a motor controller 608.The motor controller 608 may comprise one or more circuits configured toprovide a motor drive signal 624 to the motor 604 to drive the motor 604as described herein. In some examples, the motor 604 may be a brushed DCelectric motor, such as the motor 505 shown in FIG. 1. For example, thevelocity of the motor 604 may be proportional to the motor drive signal624. In some examples, the motor 604 may be a brushless direct current(DC) electric motor and the motor drive signal 624 may comprise apulse-width-modulated (PWM) signal provided to one or more statorwindings of the motor 604. Also, in some examples, the motor controller608 may be omitted and the control circuit 610 may generate the motordrive signal 624 directly.

The motor 604 may receive power from an energy source 612. The energysource 612 may be or include a battery, a super capacitor, or any othersuitable energy source 612. The motor 604 may be mechanically coupled tothe I-beam 614 via a transmission 606. The transmission 606 may includeone or more gears or other linkage components to couple the motor 604 tothe I-beam 614. A position sensor 634 may sense a position of the I-beam614. The position sensor 634 may be or include any type of sensor thatis capable of generating position data that indicates a position of theI-beam 614. In some examples, the position sensor 634 may include anencoder configured to provide a series of pulses to the control circuit610 as the I-beam 614 translates distally and proximally. The controlcircuit 610 may track the pulses to determine the position of the I-beam614. Other suitable position sensor may be used, including, for example,a proximity sensor. Other types of position sensors may provide othersignals indicating motion of the I-beam 614. Also, in some examples, theposition sensor 634 may be omitted. Where the motor 604 is a steppermotor, the control circuit 610 may track the position of the I-beam 614by aggregating the number and direction of steps that the motor 604 hasbeen instructed to execute. The position sensor 634 may be located inthe end effector 602 or at any other portion of the instrument.

The control circuit 610 may be in communication with one or more sensors638. The sensors 638 may be positioned on the end effector 602 andadapted to operate with the surgical instrument 600 to measure thevarious derived parameters such as gap distance versus time, tissuecompression versus time, and anvil strain versus time. The sensors 638may comprise a magnetic sensor, a magnetic field sensor, a strain gauge,a pressure sensor, a force sensor, an inductive sensor such as an eddycurrent sensor, a resistive sensor, a capacitive sensor, an opticalsensor, and/or any other suitable sensor for measuring one or moreparameters of the end effector 602. The sensors 638 may include one ormore sensors.

The one or more sensors 638 may comprise a strain gauge, such as amicro-strain gauge, configured to measure the magnitude of the strain inthe anvil 616 during a clamped condition. The strain gauge provides anelectrical signal whose amplitude varies with the magnitude of thestrain. The sensors 638 may comprise a pressure sensor configured todetect a pressure generated by the presence of compressed tissue betweenthe anvil 616 and the staple cartridge 618. The sensors 638 may beconfigured to detect impedance of a tissue section located between theanvil 616 and the staple cartridge 618 that is indicative of thethickness and/or fullness of tissue located therebetween.

The sensors 638 may be configured to measure forces exerted on the anvil616 by the closure drive system. For example, one or more sensors 638can be at an interaction point between the closure tube 1910 (FIGS. 1-4)and the anvil 616 to detect the closure forces applied by the closuretube 1910 to the anvil 616. The forces exerted on the anvil 616 can berepresentative of the tissue compression experienced by the tissuesection captured between the anvil 616 and the staple cartridge 618. Theone or more sensors 638 can be positioned at various interaction pointsalong the closure drive system to detect the closure forces applied tothe anvil 616 by the closure drive system. The one or more sensors 638may be sampled in real time during a clamping operation by a processoras described in FIGS. 16A-16B. The control circuit 610 receivesreal-time sample measurements to provide analyze time based informationand assess, in real time, closure forces applied to the anvil 616.

A current sensor 636 can be employed to measure the current drawn by themotor 604. The force required to advance the I-beam 614 corresponds tothe current drawn by the motor 604. The force is converted to a digitalsignal and provided to the control circuit 610.

The RF energy source 400 is coupled to the end effector 602 and isapplied to the RF cartridge 609 when the RF cartridge 609 is loaded inthe end effector 602 in place of the staple cartridge 618. The controlcircuit 610 controls the delivery of the RF energy to the RF cartridge609.

In certain arrangements of a bi-polar RF surgical instrument, thesurgical instrument can comprise opposing first and second jaws, whereineach jaw can comprise an electrode. In use, the tissue can be capturedbetween the jaws such that energy can flow between the electrodes in theopposing jaws and through the tissue positioned therebetween. Suchinstruments may have to seal many types of tissues, such as anatomicstructures having walls with irregular or thick fibrous content, bundlesof disparate anatomic structures, and/or substantially thick or thinanatomic structures.

Generally, when electrosurgical energy is applied, through electrodes,to a target tissue clamped in an electrosurgical end effector of asurgical device, heat provided to the target tissue in the target zone(e.g., near the electrodes) may be transferred laterally, damaging thetissue outside of the target zone and increasing the zone of coagulatedtissue laterally from the target zone. Excessive lateral spread of thecoagulation zone may be harmful to patients undergoing surgicalprocedures because more tissue is damaged and this may require morerecovery time. Moreover, the electrodes used to transmit theelectrosurgical energy may be typically placed on an electrically andthermally insulating material, and this may lead to overheating oftissue, which may cause more lateral thermal spread to the tissueoutside of the target zone and collateral tissue damage.

Aspects of the present disclosure may address the above noted problems.In an example aspect, an end effector may include a first jaw (e.g., acartridge and a channel) and a second jaw (e.g., anvil), a hot zone in acenter portion of the end effector, and cool zones in the side portionsof the end effector. The first jaw and the second jaw may define anelongate slot therebetween, and a cutting member is slideably receivablewithin the elongate slot to cut tissue located between the first jaw andthe second jaw. The first jaw may include electrically and thermallynonconductive insulative layers on each side of the centrally disposedelongate slot, and electrode layers configured to transmitelectrosurgical energy may be placed on the insulative layers in the hotzone. The first jaw also may include electrically insulating, thermallyconductive heat sink layers in the side portions of the first jaw in thecool zones. The heat sink layers may include tissue contacting surfacesthat may be in direct contact with the tissue when the tissue is clampedin the end effector. The heat sink layers may be configured to cool thetissue in the cool zones by transferring the heat in the tissue in thecool zones to the outside area to minimize the damage from the transferof heat from the target tissue in the hot zone to the tissue justoutside of the hot zone.

In an example aspect, the first jaw may include raised pads on each sideof the elongate slot under the electrode layers. The raised pads mayallow the electrode layers to be raised compared with the tissuecontacting surfaces of the heat sink layers so that more pressure, andultimately more heat, can be applied only to the target tissue moreprecisely while reducing the thermal spread to the lateral tissue. Theraised pads, in combination with the heat sink layers cooling the tissuejust outside of the target zone (e.g., hot zone) may lower thetemperature of the tissue just outside of the target zone significantlyand, thus, enable a physician to perform more precise sealing of tissuewithout excessive lateral thermal spread.

In an example aspect, the insulative layers may include an edge definedby a first surface facing the electrode layers and a second surfacefacing the elongate slot, and this edge may be chamfered to allow steamto escape through the elongate slot to prevent burning or overheating oftissue, preventing lateral thermal spread that may be caused by theexcessive heat from the overheating.

FIG. 19 shows a schematic cross-sectional view of an end effector 5500according to one aspect of this disclosure. The end effector 5500 mayinclude a first jaw 5505 and a second jaw 5610. In an example aspect,the first jaw 5505 may include an elongate channel 5530 (e.g., elongatechannel 1602) that is configured to operably support a cartridge (e.g.,a cartridge 5700) therein. In an example aspect, the first jaw 5505 andthe second jaw 5610 may define a slot therebetween. A cutting member(e.g., a blade or a knife member 1330) may be slideably receivablewithin the slot to cut tissue clamped within the end effector 5500. Theslot in the first jaw 5505 is an elongate slot 5560 (e.g., elongate slot1712). The elongate slot 5560 may extend from a proximate end of thefirst jaw 5505. The slot in the second jaw 5610 is an anvil slot 5630(e.g., anvil slot 1815). In an example, the slots 5560, 5630 may bedisposed in the center of the first and second jaws 5505, 5610. Inanother example, the slots 5560, 5630 may be disposed in any othersuitable places in the first and second jaws 5505, 5610.

In an example aspect, the first jaw 5505 may include a first insulativelayer 5510L and a second insulative layer 5510R. The first insulativelayer 5510L may be on the left side of the elongate slot 5560 and thesecond insulative layer 5510R may be on the right side of the elongateslot 5560. In the illustrated example, the first insulative layer 5510L,the second insulative layer, and the elongate slot 5560 are disposed ina center portion of the first jaw 5505. In an example aspect, the centerportion of the jaws 5505, 5610 may cover around ⅓-½ of the entireportions of the jaws 5505, 5610 and be located in the center thereof. Inan example aspect, the first insulative layer 5510L and the secondinsulative layer 5510R may comprise a thermally and electricallynon-conductive material such as a molded plastic.

In an example aspect, the first jaw 5505 also may include a firstelectrode layer 5540L on the first insulative layer 5510L and a secondelectrode layer 5540R on the second insulative layer 5510R. The firstelectrode layer 5540L and the second electrode layer 5540R may beconfigured for direct application of electrosurgical energy (e.g., RFenergy) to the tissue (T) to form a hemostatic (coagulation orcauterization) line on the tissue adjacent the electrode layers 5540L,5540R along the elongate slot 5560. The first electrode layer 5540L andthe second electrode layer 5540R may be located in the center portion ofthe first jaw 5505. In an example aspect, the first electrode layer5540L and the second electrode layer 5540R may include a direct contactmetal electrode. In an example aspect, each of the first electrode layer5540L and the second electrode layer 5540R may further include a flexcircuit. In this case, the direct contact metal electrode may bedeposited on the flex circuit. In an example aspect, the first electrodelayer 5540L and the second electrode layer 5540R may define a hot zone5650 near the first and second electrode layers 5540L, 5540R. Asillustrated in FIG. 19, the hot zone 5650 may be in the center portionof the end effector 5500 (and the first and second jaws 5505, 5610).

In an example aspect, the first jaw 5505 may include a first heat sinklayer 5520L in a left side portion of the first jaw 5505 and a secondheat sink layer 5520R in a right side portion of the first jaw 5505. Thefirst heat sink layer 5520L may include a first tissue contactingsurface 5525L, and the second heat sink layer 5520R may include a secondtissue contacting surface 5525R. The tissue contacting surfaces 5525L,5525R may be in direct contact with the tissue (T) when the tissue (T)is clamped in the end effector 5500. In an example aspect, the firstheat sink layer 5520L may define a first cool zone 5660 in the left sideportion of the end effector 5500 (or the first jaw 5505) and the secondheat sink layer 5520R may define a second cool zone 5670 in the rightside portion of the end effector 5500 (or the first jaw 5505). The firstheat sink layer 5520L and the second heat sink layer 5520R may beconfigured to cool the tissue (T) in the first and second cool zones5560, 5570 to minimize the transfer of heat from the tissue in the hotzone 5650 to the tissue outside of the hot zone 5560, preventing damagesto the tissue just outside of the hot zone 5560 (and ultimately justoutside of the end effector 5500). In an example aspect, the first andsecond heat sink layers 5520L, 5520R may be made of an electricallyinsulating, thermally conductive material, such as a ceramic material(e.g., aluminum nitride) to dissipate heat from the tissue adjacent theheat sink layers 5520L, 5520R.

In an example aspect, the first and second insulative layers 5510L,5510R may be around 0.01-0.10 inches away from a center line C of theend effector 5500. In an example aspect, the horizontal distance 5555between the electrode layer 5540L/5540R and the center line C may be inthe range of about 0.01 inches to 0.10 inches. In an example aspect, thefirst and second heat sink layers 5520L, 5520R may be around 0.03-0.20inches away from the center line C.

In an example aspect, the first electrode layers 5540L and the firstheat sink layers 5520L may define a first horizontal distance 5545Lbetween the first electrode layers 5540L and the first heat sink layers5520L. Similarly, the second electrode layers 5540R and the second heatsink layers 5520R may define a second horizontal distance 5545R betweenthe second electrode layers 5540R and the second heat sink layers 5520R.The first and second horizontal distances 5545L, 5545R may be very smallto provide a precise tissue sealing for a thin profile end effector withno or little lateral thermal spread. In an example aspect, the first andsecond horizontal distances 5545L, 5545R may be in the range of 0.00 toabout 0.50 inches, preferably in the range of about 0.00 to 0.10 inches,more preferably in the range of 0.00 to about 0.03 inches. In an exampleaspect, the first and second horizontal distances 5545L, 5545R may beless than half of the width of the electrode layers 5540L, 5540R. Inanother example aspect, the first and second horizontal distances 5545L,5545R may have any other suitable length.

In an example aspect, the first jaw 5505 may include a feature that isconfigured to apply a pressure to the tissue by the first electrodelayer 5540L and the second electrode layer 5540R in the hot zone 5650that is greater than a pressure applied to the tissue (T) by the tissuecontacting surfaces 5525L, 5525R of the first and second heat sinklayers 5520L, 5520R. In an example aspect, this feature may comprise afirst raised pad 5550L and a second raised pad 5550R. The first raisedpad 5550L and the second raised pad 5550R may allow the first electrodelayer 5540L and the second electrode layer 5540R to be raised comparedwith the tissue contacting surfaces 5525L, 5525R so that more pressure,and ultimately more heat, can be applied only to a target tissue (e.g.,tissue in the hot zone 5650 adjacent the electrode layers 5540L, 5540R)more precisely with less lateral thermal spread.

Generally, the thickness of typical electrodes itself may be too thin toprovide a meaningful pressure to compress the target tissue so that theenergy and heat can be centered in the target tissue with less lateralthermal spread. In an example aspect, the raised pads 5550L, 5550R maynot include the electrode layers 5540L, 5540R. The raised pads 5550L,5550R may comprise the insulative layers 5510L, 5510R, or a combinationof the insulative layers 5510L, 5510R and the heat sink layers 5520L,5520R. In another example aspect, the raised pads 5550L, 5550R also mayinclude the electrode layers 5540L, 5540R in addition to the insulativelayers 5510L, 5510R and/or the heat sink layers 5520L, 5520R. In anexample aspect, the thickness of the raised pads 5550L, 5550R (e.g., thevertical distance between the electrode layers 5540L, 5540R and thetissue contacting surfaces 5525L, 5525R) may be at least three to fivetimes of the thickness of the electrode layers 5540L, 5540R. In anexample aspect, the thickness of the raised pads 5550L, 5550R may be inthe range of about 0.05 inches to 0.10 inches. In another exampleaspect, the raised pads 5550L, 5550R may have any suitable thicknessthat is sufficient to reduce the lateral thermal spread.

In an example aspect, the first insulative layer 5510L may include afirst surface 5512L facing the first electrode layer 5540L and a secondsurface 5514L facing the elongate slot 5560. The first surface 5512L andthe second surface 5514L of the first insulative layer 5510L may definea first edge 5570L. Similarly, the second insulative layer 5510R mayinclude a first surface 5512R facing the first electrode layer 5540R anda second surface 5514R facing the elongate slot 5560. The first surface5512R and the second surface 5514R of the second insulative layer 5510Rmay define a second edge 5570R. In an example aspect, the first andsecond edges 55740L, 5570R may be chamfered to allow steam to escapethrough the elongate slot 5560 to prevent burning or overheating oftissue that can lead to collateral tissue damage.

The elongate channel 5530 may be formed under the insulative layers5510L, 5510R and heat sink layers 5520L, 5520R. In an example aspect,the elongate channel 5530 may comprise a thermally conductive metallicmaterial and in direct contact with the first and second heat sinklayers 5520L, 5520R to facilitate the cooling of the tissue in the firstand second cool zones 5660, 5670. For example, the heat in the heat sinklayers 5520L, 5520R transferred from the tissue may be furthertransferred to the metallic channel 5530 and this may help reduce thetissue temperature in the cool zones 5660, 5670 more quickly.

In an example aspect, during coagulating or cutting, the averagetemperature of tissue in the cool zones 5660, 5670 may be much lowerthan the average temperature of tissue in the hot zone 5650. After thecoagulating or cutting, the temperature of tissue in the cool zones5660, 5670 may decrease more quickly than the temperature of tissue inthe hot zone 5650.

In an example aspect, the second jaw 5610 may comprise an anvil that ispivotally supported relative to the elongate channel 5530. The secondjaw 5610 may be selectively moved toward and away from a surgicalcartridge supported in the elongate channel 5630 between open and closedpositions by actuating a closure drive system (e.g., closure drivesystem 510). In FIG. 19, the end effector 5500 is in a closed positionwith tissue (T) clamped between the first jaw 5505 and the second jaw5610. The anvil slot 5630 may open into an upper opening 5640 that iswider than the anvil slot 5630 as shown in FIG. 19. The upper openingmay extend longitudinally through the second jaw 5610, for example, toaccommodate the anvil engagement features (e.g., anvil engagementfeature 1336) on the cutting member (e.g., knife member 1330) duringfiring. The second jaw 5610 also may include fastener forming pockets5620 (e.g., fastener forming pockets 1814) formed therein on each sideof the anvil slot 5630.

FIG. 20 shows a perspective view of the end effector 5500 according toone aspect of this disclosure. In FIG. 20, the end effector 5500 is inan open position. The second jaw 5610 may be moveable relative to thefirst jaw 5505. The first jaw 5505 may include a cartridge 5700 that issized and shaped to be removably received and supported in the elongatechannel 5530. In an example aspect, the cartridge 5700 may include theinsulative layers 5510L, 5510R, the heat sink layers 5520L, 5520R, andthe electrode layers 5540L, 5540R. In an example aspect, a distal end ofthe first electrode layer 5540L may be connected to a distal end of thesecond electrode layer 5540R as shown in FIG. 20, and the elongate slot5560 may extend through the center of the electrodes 5540L, 5540R. Inanother example aspect, the first electrode layer 5540L may be separatefrom the second electrode layer 5540R. The first tissue contactingsurface 5525L of the first heat sink layer 5520L may be disposed on theleft side of the first electrode layer 5540L, and the second tissuecontacting surface 5525R of the second heat sink layer 5520R may bedisposed on the right side of the second electrode layer 5540R.

The first jaw 5505 may include a microchip 5710 in the distal portion ofthe first jaw 5505. The microchip 5710 may be configured to control theelectrode layers 5540L, 5540R (e.g., providing electrosurgical energy).The microchip 5710 may be connected to a flexible cartridge circuit 5720(e.g., flexible cartridge circuit 1750), which may in turn connected toa channel circuit (e.g., channel circuit 1670). The first jaw 5505 alsomay include a dissector electrode 5730 at a distal end 5740. Thedissector electrode 5730 may be connected to a source of electricalenergy (e.g., RF generator 400) and configured to transmitelectrosurgical energy (RF energy) to the tissue for dissecting thetissue and/or coagulating blood. The dissector electrode 5730 may beisolated from and operated separately from the electrode layers 5540L,5540R.

Aspects of the surgical instrument may be practiced without the specificdetails disclosed herein. Some aspects have been shown as block diagramsrather than detail. Parts of this disclosure may be presented in termsof instructions that operate on data stored in a computer memory.Generally, aspects described herein which can be implemented,individually and/or collectively, by a wide range of hardware, software,firmware, or any combination thereof can be viewed as being composed ofvarious types of “electrical circuitry.” Consequently, “electricalcircuitry” includes electrical circuitry having at least one discreteelectrical circuit, electrical circuitry having at least one integratedcircuit, electrical circuitry having at least one application specificintegrated circuit, electrical circuitry forming a general purposecomputing device configured by a computer program (e.g., a generalpurpose computer or processor configured by a computer program, which atleast partially carries out processes and/or devices described herein),electrical circuitry forming a memory device (e.g., forms of randomaccess memory), and/or electrical circuitry forming a communicationsdevice (e.g., a modem, communications switch, or optical-electricalequipment). These aspects may be implemented in analog or digital form,or combinations thereof.

The foregoing description has set forth aspects of devices and/orprocesses via the use of block diagrams, flowcharts, and/or examples,which may contain one or more functions and/or operation. Each functionand/or operation within such block diagrams, flowcharts, or examples canbe implemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof. Inone aspect, several portions of the subject matter described herein maybe implemented via Application Specific Integrated Circuits (ASICs),Field Programmable Gate Arrays (FPGAs), digital signal processors(DSPs), Programmable Logic Devices (PLDs), circuits, registers and/orsoftware components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components, logic gates, or otherintegrated formats. Some aspects disclosed herein, in whole or in part,can be equivalently implemented in integrated circuits, as one or morecomputer programs running on one or more computers (e.g., as one or moreprograms running on one or more computer systems), as one or moreprograms running on one or more processors (e.g., as one or moreprograms running on one or more microprocessors), as firmware, or asvirtually any combination thereof, and that designing the circuitryand/or writing the code for the software and or firmware would be wellwithin the skill of one of skill in the art in light of this disclosure.

The mechanisms of the disclosed subject matter are capable of beingdistributed as a program product in a variety of forms, and that anillustrative aspect of the subject matter described herein appliesregardless of the particular type of signal bearing medium used toactually carry out the distribution. Examples of a signal bearing mediuminclude the following: a recordable type medium such as a floppy disk, ahard disk drive, a Compact Disc (CD), a Digital Video Disk (DVD), adigital tape, a computer memory, etc.; and a transmission type mediumsuch as a digital and/or an analog communication medium (e.g., a fiberoptic cable, a waveguide, a electrical conductord communications link, aelectrical conductorless communication link (e.g., transmitter,receiver, transmission logic, reception logic, etc.).

The foregoing description of these aspects has been presented forpurposes of illustration and description. It is not intended to beexhaustive or limiting to the precise form disclosed. Modifications orvariations are possible in light of the above teachings. These aspectswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the aspects and with modifications as are suited to theparticular use contemplated. It is intended that the claims submittedherewith define the overall scope.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

Example 1. An surgical instrument comprising: an end effectorcomprising: a first jaw; a second jaw that is movable relative to thefirst jaw; a hot zone in a center portion of the end effector; a firstcool zone in a left side portion of the end effector; and a second coolzone in a right side portion of the end effector; and an elongate slotdefined between the first jaw and the second jaw, the elongate slotconfigured to slideably receive a cutting member within the elongateslot to cut tissue located between the first jaw and the second jaw,wherein the elongate slot is located in the center portion of the endeffector; wherein the first jaw comprises: a first insulative layer inthe hot zone, wherein the first insulative layer is on the left side ofthe elongate slot; a second insulative layer in the hot zone, whereinthe second insulative layer is on the right side of the elongate slot; afirst electrode layer on the first insulative layer; a second electrodelayer on the second insulative layer, wherein the first electrode layerand the second electrode layer are configured for direct application ofelectrosurgical energy to the tissue in the hot zone; a first heat sinklayer in the first cool zone; and a second heat sink layer in the secondcool zone, wherein the first heat sink layer and the second heat sinklayer are configured to cool the tissue in the first and second coolzones to minimize lateral thermal spread.

Example 2. The surgical instrument of Example 1, wherein each of thefirst and second heat sink layers comprises a thermally conductiveceramic material.

Example 3. The surgical instrument of one or more Example 1 throughExample 2, wherein each of the first electrode layer and the secondelectrode layer comprises a direct contact metal electrode.

Example 4. The surgical instrument of Example 3, wherein each of thefirst electrode layer and the second electrode layer further comprises aflex circuit wherein the direct contact metal electrode is deposited onthe flex circuit.

Example 5. The surgical instrument of one or more Example 1 throughExample 4, wherein each of the first heat sink layer and the second heatsink layer comprises a tissue contacting surface.

Example 6. The surgical instrument of Example 5, wherein each of thefirst electrode layer and the second electrode layer are raised comparedwith the tissue contacting surfaces of the first heat sink layer and thesecond heat sink layer, which allows the end effector to apply apressure to the tissue by the first electrode layer and the secondelectrode layer in the hot zone that is greater than a pressure appliedto the tissue by the tissue contacting surfaces of the first heat sinklayer and the second heat sink layer.

Example 7. The surgical instrument of one or more Example 1 throughExample 6, wherein the first insulative layer and the second insulativelayer comprise a thermally and electrically non-conductive material.

Example 8. The surgical instrument of one or more Example 1 throughExample 7, wherein the first insulative layer comprises a first surfacefacing the first electrode layer and a second surface facing theelongate slot, wherein the first surface and the second surface define afirst edge, wherein the first edge is chamfered to allow steam toescape.

Example 9. The surgical instrument of Example 8, wherein the secondinsulative layer comprises a third surface facing the second electrodelayer and a fourth surface facing the elongate slot, wherein the thirdsurface and the fourth surface define a second edge, wherein the secondedge is chamfered to allow the steam to escape.

Example 10. The surgical instrument of one or more Example 1 throughExample 9, wherein the first jaw further comprises a channel under thefirst and second heat sink layers.

Example 11. The surgical instrument of Example 10, wherein the channelcomprises a thermally conductive metallic material, and the channel isin direct contact with the first and second heat sink layers tofacilitate the cooling of the tissue in the first and second cool zones.

Example 12. An surgical instrument comprising: an end effectorcomprising: a first jaw; a second jaw that is movable relative to thefirst jaw; a hot zone in a center portion of the end effector; a firstcool zone in a left side portion of the end effector; a second cool zonein a right side portion of the end effector; and a dissector tip at adistal end of the end effector; and an elongate slot defined between thefirst jaw and the second jaw, the elongate slot configured to slideablyreceive a blade within the elongate slot to cut tissue located betweenthe first jaw and the second jaw, wherein the elongate slot is locatedin the center portion of the end effector; wherein the first jawcomprises: a first insulative layer in the hot zone, wherein the firstinsulative layer is on the left side of the elongate slot; a secondinsulative layer in the hot zone, wherein the second insulative layer ison the right side of the elongate slot; a first electrode layer on thefirst insulative layer; a second electrode layer on the secondinsulative layer, wherein the first electrode layer and the secondelectrode layer are configured for direct application of electrosurgicalenergy to the tissue in the hot zone, wherein each of the firstelectrode layer and the second electrode layer comprises a directcontact metal electrode; a first heat sink layer in the first cool zone;and a second heat sink layer in the second cool zone, wherein the firstheat sink layer and the second heat sink layer are configured to coolthe tissue in the first and second cool zones to minimize lateralthermal spread.

Example 13. The surgical instrument of Example 12, wherein each of thefirst and second heat sink layers comprises a thermally conductiveceramic material.

Example 14. The surgical instrument of one or more Example 12 throughExample 12, wherein each of the first electrode layer and the secondelectrode layer further comprises a flex circuit wherein the directcontact metal electrode is deposited on the flex circuit.

Example 15. The surgical instrument of one or more Example 12 throughExample 14, wherein each of the first heat sink layer and the secondheat sink layer comprises a tissue contacting surface.

Example 16. The surgical instrument of Example 15, wherein each of thefirst electrode layer and the second electrode layer are raised comparedwith the tissue contacting surfaces of the first heat sink layer and thesecond heat sink layer, which allows the end effector to apply apressure to the tissue by the first electrode layer and the secondelectrode layer in the hot zone that is greater than a pressure appliedto the tissue by the tissue contacting surfaces of the first heat sinklayer and the second heat sink layer.

Example 17. The surgical instrument of one or more Example 12 throughExample 16, wherein the first insulative layer and the second insulativelayer comprise a thermally and electrically non-conductive material.

Example 18. The surgical instrument of one or more Example 12 throughExample 17, wherein the first insulative layer comprises a first surfacefacing the first electrode layer and a second surface facing theelongate slot, wherein the first surface and the second surface define afirst edge, wherein the first edge is chamfered to allow steam toescape.

Example 19. The surgical instrument of one or more Example 12 throughExample 18, wherein the first jaw further comprises a channel under thefirst and second heat sink layers.

Example 20. The surgical instrument of Example 19, wherein the channelcomprises a thermally conductive metallic material, and the channel isin direct contact with the first and second heat sink layers tofacilitate the cooling of the tissue in the first and second cool zones.

The invention claimed is:
 1. A surgical instrument comprising: an endeffector comprising: a first jaw; a second jaw that is movable relativeto the first jaw; a hot zone in a center portion of the end effector; afirst cool zone in a left side portion of the end effector; a secondcool zone in a right side portion of the end effector; and an elongateslot defined between the first jaw and the second jaw, the elongate slotconfigured to slideably receive a cutting member within the elongateslot to cut tissue located between the first jaw and the second jaw,wherein the elongate slot is located in the center portion of the endeffector; and wherein the first jaw comprises: a first thermally andelectrically insulative layer in the hot zone, wherein a left side ofthe elongate slot is defined by a first insulative surface of the firstthermally and electrically insulative layer; a second thermally andelectrically insulative layer in the hot zone, wherein a right side ofthe elongate slot is defined by a second insulative surface of thesecond thermally and electrically insulative layer; a first electrodelayer on the first thermally and electrically insulative layer; a secondelectrode layer on the second thermally and electrically insulativelayer, wherein the first electrode layer and the second electrode layerare configured for direct application of electrosurgical energy totissue in the hot zone; a first heat sink layer in the first cool zone;a second heat sink layer in the second cool zone, wherein the first heatsink layer and the second heat sink layer are configured to cool tissuein the first and second cool zones to minimize lateral thermal spread;and a channel under the first heat sink layer and the second heat sinklayer, wherein the channel comprises a thermally conductive material,and wherein: the first thermally and electrically insulative layercontacts an inner surface of the first heat sink layer and an innersurface of the channel; and the second thermally and electricallyinsulative layer contacts an inner surface of the second heat sink layerand the inner surface of the channel.
 2. The surgical instrument ofclaim 1, wherein each of the first and second heat sink layers comprisesa thermally conductive ceramic material.
 3. The surgical instrument ofclaim 1, wherein each of the first electrode layer and the secondelectrode layer comprises a direct contact metal electrode.
 4. Thesurgical instrument of claim 3, wherein each of the first electrodelayer and the second electrode layer further comprises a flex circuit,and wherein the direct contact metal electrode is deposited on the flexcircuit.
 5. The surgical instrument of claim 1, wherein each of thefirst heat sink layer and the second heat sink layer comprises a tissuecontacting surface.
 6. The surgical instrument of claim 5, wherein eachof the first electrode layer and the second electrode layer are raisedcompared with the tissue contacting surfaces of the first heat sinklayer and the second heat sink layer, which allows the end effector toapply a pressure to tissue by the first electrode layer and the secondelectrode layer in the hot zone that is greater than a pressure appliedto tissue by the tissue contacting surfaces of the first heat sink layerand the second heat sink layer.
 7. The surgical instrument of claim 1,wherein the first thermally and electrically insulative layer and thesecond thermally and electrically insulative layer comprise a thermallyand electrically non-conductive material.
 8. The surgical instrument ofclaim 1, wherein the first thermally and electrically insulative layerfurther comprises a first surface facing the first electrode layer,wherein the first surface and the first insulative surface define afirst edge, and wherein the first edge is chamfered to allow steam toescape.
 9. The surgical instrument of claim 8, wherein the secondthermally and electrically insulative layer further comprises a secondsurface facing the second electrode layer, wherein the second surfaceand the second insulative surface define a second edge, and wherein thesecond edge is chamfered to allow the steam to escape.
 10. The surgicalinstrument of claim 1, wherein the thermally conductive materialcomprises a thermally conductive metallic material, and wherein thechannel is in direct contact with the first and second heat sink layersto facilitate cooling of the tissue in the first and second cool zones.11. An end effector for use with a surgical instrument to effect atissue treatment, the end effector comprising: a first jaw; a second jawconfigured to cooperate with the first jaw to grasp tissue therebetween;a hot zone in a center portion of the end effector; a first cool zone ina first side portion of the end effector; a second cool zone in a secondside portion of the end effector opposite the first side portion; and anelongate slot extending along a length of the end effector, wherein theelongate slot comprises a first wall and a second wall, wherein theelongate slot is configured to slideably receive a cutting membermovable between the first wall and the second wall to cut the tissuelocated between the first jaw and the second jaw; and wherein the firstjaw comprises: a first thermally and electrically insulative layer inthe hot zone, wherein the first wall of the elongate slot is defined bythe first thermally and electrically insulative layer; a secondthermally and electrically insulative layer in the hot zone, wherein thesecond wall of the elongate slot is defined by the second thermally andelectrically insulative layer; a first electrode layer on the firstthermally and electrically insulative layer; a second electrode layer onthe second thermally and electrically insulative layer, wherein thefirst electrode layer and the second electrode layer are configured fordirect application of electrosurgical energy to tissue in the hot zone;a first heat sink layer in the first cool zone; a second heat sink layerin the second cool zone, wherein the first heat sink layer and thesecond heat sink layer are configured to cool tissue in the first andsecond cool zones to minimize lateral thermal spread; and a channelunder the first heat sink layer and the second heat sink layer, whereinthe channel comprises a thermally conductive material, and wherein: thefirst thermally and electrically insulative layer contacts an innersurface of the first heat sink layer and an inner surface of thechannel; and the second thermally and electrically insulative layercontacts an inner surface of the second heat sink layer and the innersurface of the channel.
 12. The end effector of claim 11, wherein eachof the first and second heat sink layers comprises a thermallyconductive ceramic material.
 13. The end effector of claim 11, whereineach of the first electrode layer and the second electrode layercomprises a direct contact metal electrode.
 14. The end effector ofclaim 13, wherein each of the first electrode layer and the secondelectrode layer further comprises a flex circuit, and wherein the directcontact metal electrode is deposited on the flex circuit.
 15. The endeffector of claim 11, wherein each of the first heat sink layer and thesecond heat sink layer comprises a tissue contacting surface.
 16. Theend effector of claim 15, wherein each of the first electrode layer andthe second electrode layer are raised compared with the tissuecontacting surfaces of the first heat sink layer and the second heatsink layer, which allows the end effector to apply a pressure to tissueby the first electrode layer and the second electrode layer in the hotzone that is greater than a pressure applied to tissue by the tissuecontacting surfaces of the first heat sink layer and the second heatsink layer.
 17. The end effector of claim 11, wherein the firstthermally and electrically insulative layer and the second thermally andelectrically insulative layer comprise a thermally and electricallynon-conductive material.
 18. The end effector of claim 11, wherein thefirst thermally and electrically insulative layer comprises a firstsurface facing the first electrode layer and a second surface facing theelongate slot, wherein the first surface and the second surface define afirst edge, and wherein the first edge is chamfered to allow steam toescape.
 19. The end effector of claim 18, wherein the second thermallyand electrically insulative layer comprises a third surface facing thesecond electrode layer and a fourth surface facing the elongate slot,wherein the third surface and the fourth surface define a second edge,and wherein the second edge is chamfered to allow the steam to escape.20. An end effector comprising: a first jaw; a second jaw, wherein thefirst jaw and the second jaw are configurable relative to one another tocapture tissue there between; and a channel comprising a thermallyconductive material; wherein the first jaw comprises: a hot zone,comprising: an elongate slot configured to slideably receive a cuttingmember; a first thermally and electrically insulative layer, wherein afirst side of the elongate slot is defined by a surface of the firstthermally and electrically insulative layer; a first electrode layerpositioned on the first thermally and electrically insulative layer; asecond thermally and electrically insulative layer, wherein a secondside of the elongate slot is defined by a surface of the secondthermally and electrically insulative layer; and a second electrodelayer positioned on the second thermally and electrically insulativelayer; a first cool zone on a first lateral side of the hot zone,wherein the first cool zone comprises a first heat sink layer; and asecond cool zone on a second lateral side of the hot zone, wherein thesecond cool zone comprises a second heat sink layer, and wherein thefirst heat sink layer and the second heat sink layer are configured tocool tissue to minimize lateral thermal spread; wherein the channel isunder the first heat sink layer and the second heat sink layer, andwherein: the first thermally and electrically insulative layer isconfigured to contact an inner surface of the first heat sink layer andan inner surface of the channel; and the second thermally andelectrically insulative layer is configured to contact an inner surfaceof the second heat sink layer and the inner surface of the channel.